Home

service manual FPI 5000 I

1. land electron 1ca f the FPI 5000 I electr iew and sensor actuator connections Overv figure 1 2 510 03 13 rev 01 0 01 2002 service manual FPI 5000 I Power Drivers CPU Photo Syscon figure 1 3 The main board 94 80 01 electronics are divided into five sections items in a specific section are numbered from X00 onwards X 1 5 510 03 14 rev 01 0 01 2002 FPI 5000 I service manua 90718207 AS tVNV AS VNV oein O bdL en aH 2 SL8ZIN1 0211 ASI 02441 yursjesy 00141 QNO GN9d W EL VOOVNI NOOL NOOL 310022 70 0 012 20 2 DOA VAN 9WAN 89 22A AS 1013 041 99 Noo 612 9 9507771 0611 ML ML 06 8 JOWUOWAS 299 9910 2 NC V AVE 0814 1 ML NOOL 3100727 1219 0219 ve _ zo Ave Z 002 T Ave mE 82d 19V Id LON 33A i 1 00 NOU 1919 0919 0119 _ L AVE E 99 4 9189 s L Ave 00Z vavnax 1 U0N98
2. 0370 ova m 2 a 6 T 0 ta jeoueg Je9 2 dois uelis 5 dno 2 5 EC K Szzdr veces 19 19 zes 19 zs 19 ZN ZN ZN 822g zza 922g ezza zzza 1220 10N 0 QNO ghey 2 00 0120 T I E E 9125 19 v zs sizs 9 zs 19 1129 IN ZN siza 917G siza vica giza EA ZA 4 Lo 9 LA 0A V N BV 17109 6ELLOHPZ 9109 L 109 vi vg 100 SL 109 e ca 102 0 109 8L SKZLOHYL 2 2 1 2 Lv 2 2 Len H keys 1085 t board 95 70 72 electroni The combined display key circui figure 1 16 510 03 25 rev 01 0 01 2002 service manual co RO00 1 210 33 TH us ZN D228 D218 D227 0217 0226 D216 D225 D215 D224 D214 D223 D213 D222 D212 D221 D211 LITI9V8 149 D P228 P227 P226 JP225 5217 5216 c2a20L 1 5215 TO LM7420PLFG R141 R140 R41 FH R35 FH R156 FH 7 __
3. KY 5760 W 4 4 V AJ M D RS Oe P 9 et AR A 7 CNN Ree SOON A 96 Nei ES QUE N wy ro S CY 7 jS 131211 1O LD 1716 15 14 22 212019 18 figure 6 3 rev 01 0 01 2002 510 02 49 service manual FPI 5000 I Set of upper insert rollers 42 5 mm Removal Refer to figure 6 2 Remove the two round head screws 17 securing the bracket 16 and place the bracket as de Refer to figure 6 3 Remove the round head screws 13 the washers 12 and the guides 11 from both s des of the axle 8 Slacken the set screw of the roller 7 and slide it off the axle Slacken the set screw of the roller 10 and slide it off the axle Replacement When retightening the set screws ensure that there is only a slight amount of axial play on the axle Adjustment See paragraph 10 11 Upper insert rollers loc First set of upper ejection rollers 38 mm Removal Refer to figure 6 3 Slacken the set screw of the roller 6 and slide it off the axle Take care of the washer 5 and spacer 4 Slacken the set screw of the roller 1 and slide it off the axle Take care of the washer 2 and spacer 3 Replacement When retightening the set screws ensure that there is only a slight amount of axial play on the axle 6 3 2 Gears Gear 20T item 8 Removal Refer to figure 6 3 Remove the round head screws 13 the washers 12 and the guides 11 from both s des of the axle 8 Unhook the two tensio
4. NOOL NOOL NOOL NOOL NOOL NOOL NOOL NOOL zi 5660 075620 0 0220 089 AHAND 098 9 AND 0520 ii HOLVYIS OL noo HOLVYOS Loedr 5 HO1VMNOS 0 9 y 9 4H2910 O 99A 5 1004 NOH bb a lt ZIY NOU 11 Teen ooer NON SA lt SH i 6 ossen WIS vas 5 9 iz 00 wis 19s S s S gt __ 21 assen 1x3 Days 7 2 L i eye 4H294 8010 ELSLOHVZ OVSLOHYL eye red sd vssen osen ogen gz SIG lt __ 5 DE La 29 lt ___ aNvaxa 1 B ONOJ ISNI THS 1287 A a SSAV ozy 9 99av soed T S sav 22 IAY en J3HAV zoav 19 O AS VNV Loav 224 09av 15 m rare 26054 LIND 0 coer 9 vd 0112 64512 I 1 0 vMSIWO 0Lv S 449NI4 gt LYSIND WIS 125 vyd 045100 7 11x3 er 1 N 001 L__0 4 gt 00L lt GUN Led dy SIJESIG lt ___ 51 N 5195805 Beh Z LE 9 d 1216 CN an aa aw N e ML 2 2
5. ML 8 ASA NOSTI VY lt v AL NL ocen 4 0 22 H8S WT1 z 2 5 vorzn ozzr NOL 272 dl INI MOVYL ANI sii T zzzu 99 99 as lt g THE H8S N7 zuz MOOL 9 GN9V 01209 AS VNV NOOL MOL Wzo 9024 dey 16 secu m NOOL wa E orza 2 L MOL 1 829 2823 V A AZL AS WNV lt ___ 11X3 s AS UN 9 11804 zezo uem ris vas gt lt NIS 125 gt gt 57 WIS 19S z 1 105 LOS ssi39NIJ 9 oL sos 6 11X3 tg ki Lyvrsval XY dV14 xovul ANY dean HSE HOY 9 6 _ NOOL LIXA Aud lt 08209 vHd XY LIX3 i MOVAL MOL ASI 0024 71072015 8032015 oszr J043uo sseujubiuq V184W1 Jepues AC Lezn 92030 10 l 3nduj photocells and DFC unit 2 ICS board 94 80 01 electroni in Ma figure 1 5 rev 01 0 01 2002 510 03 16 FPI 5000 I service
6. N azal rs 5 pe Ne 7179 B 48 orzn 0920 OFEN GYGY 02 0 4540 Component layout of the ma 1 DISPLAY 1 2 figure 1 9 510 03 20 service manual 5V 7 5V 7 R703E IN 1N4148 10K 710 D711 1N4148 MicroCan Clip GND 7 GND 7 5V 7 A 5V 7 C700 100N GND 7 FM24C16 figure 1 10 The FRAM board 95 74 55 electronics rev 01 0 01 2002 FPI 5000 I MicroCan Clip for optional DS199x Outer pin 15 710 See DALLAS Automatic Identification Data Book page132 J700 MicroMatch12 510 03 21 service manual FPI 5000 I 95 74 55 D711 C700 figure 1 11 Component layout of the FRAM board 95 74 55 QD 220 240V 2 R2 33K BLEEDER 100 120V figure 1 12 The motor relay board 12 16 21 electronics 510 03 22 rev 01 0 01 2002 service manual FPI 5000 I Al gt __ O 74 220 240V 100 1 CM 121621 igalBjc D figure 1 13 Component layout of the motor relay board 12 16 21 8 2 D DE JA
7. 4 2 3 Clutches Slip clutch The removal procedure of the slip clutch has been described in paragraph 4 2 1 First set of transportation rollers 36 mm Freewheel clutch The removal procedure of the freewheel clutch has been described in paragraph 4 2 2 Gear 28T item 4 and gear 19 item 5 rev 01 0 01 2002 510 02 39 service manual FPI 5000 I 5 Document feed Remove the RH s de cover as described n paragraph 1 3 RH side cover Remove the front cover plate as described n paragraph 1 7 Front cover plate 5 1 Upper transportation rollers First set of upper transportation rollers 36 mm figure 5 1 Removal Refer to figure 5 1 Slacken the set screws of the two transportation rollers 8 Remove the spring clips 7 from both sides of the transportation axle 9 Carefully withdraw the transportation axle in the right hand side direction out of the machine and slide the two rollers off it Take care that the bearings 11 with the pressure springs 12 on both sides of the transportation axle stay in place and of the washers 10 on both sides Replacement Ensure on replacement that the two transportation rollers are refitted correctly on the transportation axle narrowing part of both rollers pointing inwards and the set screws rest into the grooves in the transportation axle 510 02 40 rev 01 0 01 2002 service manual FPI 5000 I Second set of upper transportation rollers 36 mm Removal Refer
8. ICS board 94 80 01 electroni in Mai figure 1 6 510 03 17 rev 01 0 01 2002 FPI 5000 I service manua 9 205 v zos 1oara E o we 4 Hd X1 201 ERR 8012035 oorr MOVYL 11908 0270 gt z ML 259 105 voori 57 201 Qz Hsnua 8 448072 S 103193r3 Z 8 MOVYL 6 0990 z MPH 11908 Buiees 0270 L voorN 7 z ML 105 H35NH pera Lobo 9 vo jur cra 145 11908 d 4 0570 b 2 A 105 3 3 Il VOOVNL 7 6 diii ostra JUL Ave 2 Nvz 11898 0070 Erd amp d HOLOW Ska 11908 qzesva anog 99 Z eye ges sory 1804 yOOPNI sovo Z __ orta ML 1 d AvidH lNVIS pore Ave Teesvg N 7 m 9072 Ot cLOHTA 0 OvVZLOHPL voorn 104193f3 MOVYL LL y 18534 5 03 HOLON board 94 80 01 electron e FQ 14VLS YOLOW Ivers actuator dri 4 ICS Main figure 1 7 rev 01 0 01 2002
9. S6 ved ou lt vas gt aa lt 08X d 22 195 SH 1Z gt 8 Z say T 342240 HI OLNI BEE 8 ved 1x3 t 8v 0 d 2910 O 99A L av MOL 0ZU23e NOJ9 IA ody LL 0 7 9 020 c Sv DS oven 219 2 1 vr vid 3215 90 pue lt Sv nos z in aly 87 99 oiv LY 121 Sm 000 Sv or zd D s 00L LLEN 8v 6 vas IL I gt zi 9 Ld 126 WIS vas lt sia WON gt EM TAVIS HOION 1 nis S U 6 139 2 SAS Vid 21 13534 9 5 139435019 E LAIELII SLNI 1x3 5 00V ILNOI Z bd IZLO PLNI 1SM SI as 9910 2 i 92A ay SRI ocio ozer 9 0d Z1WLX LS 2 04 ve sav 25 vd dzz 92 HA 0 2020 qv HON tqv _ 79 zav SS 04 3 02 SL vod A VIV LY SE Dan SH 90 z dzz as 255208 sid Loco LL ooen WIS Vas AHOOA 6 WIS 126 gt 5 er gt sid v 0gv 22 2 0ZU23e NOJ9 IN 0109 7 af a 2 zuer ocen 4H99N msa Zav oav 77707 3 CPU circuitry
10. ano odas 703906 LP A82 lt gt lolav de il 39euuo AND 98xng P P om A0SZ AJE 4822 duge lt 13934 _ 9 1 1 VOOr E uo 4 paeoq 9 16987 98XNg Dv nu 010 200 LOLO 4100 2 OTIC oi OLLO 2 276 2 mE 2050016 diea a 0011 0013 Abc Ae ere 20141 LOLd L d LCD power supplies an ICS t board 95 70 72 electroni ircui lay key ci isp The combined d figure 1 15 control rev 01 0 01 2002 510 03 24 SA IMS00 service a3T 9205 9005 21008 8005 ASt eu191XJ jeuediuoH O d ozzy 0 VG aNd M04HO e 001 0229 0029 1 A 7 g v 20 9 A 9 b 1 0224 LL 69 e SI L lt Si s 00 1 a SOA OA v govg 9 9 99 SEa 6ELLOHPL yo goozn
11. 5 5 x 8mm Rubber stud M5 x 20 Inside frame LH 05 24 47 04 01 22 45 37 43 73 55 41 03 35 35 05 38 68 73 55 40 05 38 69 04 23 43 12 14 15 05 24 31 05 38 71 23 56 27 95 73 07 33 55 39 03 11 90 43 34 27 05 36 21 43 29 50 05 24 42 04 01 43 04 09 34 05 24 92 43 34 26 45 43 17 43 26 64 43 11 12 04 24 26 05 24 56 03 11 11 45 38 68 04 18 35 13 22 82 23 28 88 45 38 65 04 01 29 95 73 14 73 22 61 12 14 89 05 38 80 45 19 03 12 00 98 43 29 31 04 12 11 95 73 09 Nn N Neee c BNO RK QN BONN N O e ON m N Ne 510 04 9 Figure 510 04 8 Remarks 510 04 10 illustration code number 46 47 48 49 50 51 52 53 54 29 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 service manual Description Ball bearing with housing assy Fixing ring Fixing screw Support Countersunk screw M3 x 16 Spacer 10 x 5 3 x 5 mm Finger strip Finger synthetic part Washer 12 x 5 2 x 0 7 mm Pressure spring Knurled nut Document detector assy Spacer 10 x 5 3 x 10 mm Finger strip centre Set screw M4 x 4 Transportation roller 36 mm Spacer 15 x 10 4 x 5 mm Bushing 15 x 10 x 5 5 mm Cyl pin 2 5 x 32 Gear 35T Spring clip 10 14 mm Safety cover Tension spring 0 5 mm Clamping ring 5 mm Nut M4 Spacer 17 x 10 2 x 2 mm Transportation table assy Trans
12. 510 03 18 FPI 5000 I service manua 2S4S 6 8 L 9 g v L 6049048 Losr on L AbZ 441402 198 vas 013834 13 QNO2SAS ZL09903S oosr 18465891 v L 5042046 ovsr be Ober ADWIOJSUBCIL IOJOW 7042046 Loer 11829 0290 1 MOL 11828 5150 E 9154 qzesva s sa AvZ O 4 L AvZ O lt 1zesva O ozsa 2 001 Sl iof 6158 0154 O L poss LI osso Pus 001 E 66AV8 zosa Losa O 2 O L AvZ 99 1 MOL 2244 LAr LZS 66AV8 oosa JILYNWOLNYV O 1X4N O 139 NOO SAS Mr XJA09 NALX dOL 98ML syl 9094 vosu ML DOA MOL 9V1d 35012 1zesva V prsa MI li 2798 MOL DOA M evsu 9754 1zesva V 6 zvsa ML DOA 0vSH MOL DOA LysU 17 svg orsa DOAN 1018 AVI3M YOLOW 0 1 15 e Teesva Sisa Z N 9 54 Teesva orsa N 2194 VLOHYL dOLsn VLOHYL 301SN O NOL S 9194 0 0 54 49 6 gt VLOHYVL ao sn OL 182 gt VLOHYVL gorsn 8
13. 58 59 60 61 62 63 AN S ZM NA X AX 2 X IL E N D AN 4 4 7 34 Ih 52 Q A e eea ___ Figure 7 510 04 28 rev 02 0 02 2002 service manual FPI 5000 I Figure 510 04 28 Part code Quantity Remarks number FPI 5000 I illustration code number Remarks Description rev 02 0 02 2002 gt 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Tension pin 2 5 x 14 Upper sealing roller 36 mm Tension pin 2 5 x 16 Lower sealing roller assy 2 36 mm Spacer 0 15 x 0 10 4 x 5 mm Gear 28T Gear 18T Spring clip 9 12 mm Washer 16 x 10 2 x 0 8 mm Spacer 15 x 10 4 x 3 mm Clamping ring 10 mm Pressure spring Conductive bearing 10 mm Bearing plate assy Pulse disc sensor assy Washer 6 x 3 2 x 0 5 mm Round head screw M3 x 8 Axle for pulse disc Round head screw M3 x 8 Nut M4 Fixing plate microswitch Self locking clip Transportation axle Chain tensioner Hex head screw M4 x 8 Belt chain tightener Locking plate Spring clip 10 14 mm Round head screw M4 x 10 Washer 12 x 4 3 x 1 5 mm Conductive strip Spacer 0 8 x 0 4 3 x 5 mm Bracket assy Gear 15 Gear 15T Transportation axle Clutch shaft assy Protective cover Round head screw x 8 Wire strap holder Chain
14. L4 uvay 3415 O S o 9 VLOHYL 201SN un 2 NOOL LLSD D 1 221 O a i z 4015 1X4 O E VLOHYL vorsn gt un ee un Q m board 94 80 01 electron n Mai figure 1 8 510 03 19 rev 01 0 01 2002 FPI 5000 I service manua 010 d3MOd 1X3 1067 oosr our SIR NIN 11080 0110 NODSAS 0910 za 0011 0412 139WNN WV4 4 589 a 901 g EE I TIL UL osta 0 70 0970 mE 0061 001 0 0191 141 185 vied gt de gt ole o L a vogar JE y X NT 602 29 8 0641 0 lt 00 X OLEY 0610 261 8 C Goa OLEN 3131012181 1 10 08 6 s LL 00441 Ny 06141 SGEN iip sse 070 D 099 EIER RO ER TH 5 1 1 01 0 01 2002 vC ol lt ex 4250 07 5 90 EB B EH ozzn Sb N e i 901 1200 board 94 80 01 ven Iezn 0220 M Otta iez OVA 1069 35012 C J PET AAEE po m 7202 35 a T 0242024 Liam wo aa 24
15. The PC communication between feeder unit 2 feeders 3 and 4 and the FPI 5000 C base unit fails This error is also generated during system initialisation if the FRAM data supposes this unit to be present but it appears to be removed Error 3 52 Message Technical failure Action Call service Info Communication failure The PC communication between feeder unit 3 feeders 5 and 6 and the FPI 5000 C base unit fails This error is also generated during system initialisation if the FRAM data supposes this unit to be present but it appears to be removed Error 3 53 Message Technical failure Action Call service Info Communication failure The IC communication between the reading board and the FPI 5000 C main board fails This error is also generated during system initialisation if the FRAM data indicates that the reading board must be present but it appears to be removed Error 3 54 Message Technical failure Action Call service Info Reading card timeout During communication with the regarding board a timeout occurred rev 01 0 01 2002 510 03 69 service manual FPI 5000 I Error 3 57 Message Technical failure Action Call service Info Disc sensor failure The slotted photocell VSPHI which monitors the central FPI 5000 pulse disc doesn t deliver time base pulses for the FPI 5000 C process This may be caused by defective photocell hardware or there may be a mechanical reason Note that this p
16. components Note After changes in the configuration have been made we recommend to check in the FV config settings menu if the FRAM has been updated If this is not the case press Reset configuration After message restart system to set new configuration switch the machine off and on again The FRAM will then be updated Note The jumper settings on the feeder boards 93 06 02 are not stored in FRAM but are read at the start of each machine session FY CONFIG SETTINGS Humber of feeders Daily mail on feeder DFC present on feeder Gap separation Divert present Readingcard present Reset configuration figure 3 16 The FV CONFIG SETTINGS menu 3 3 3 The FV SERVICE TESTS menu This menu see consists of the following four menus Photocell condition figure 3 18 Digital inputs figure 3 19 Actuator tests figure 3 20 DFC test figure 3 22 rev 01 0 01 2002 nur WN gt 6 510 03 39 service manual FPI 5000 I PHOTO CONDITIONGT FY PHOTO CONDITION 2 current voltage paper status 0145 0 0 015 0 01 VT 017 1 1V Collator 036 1251 1 0 017 11 020 1 1 Press lt gt to reset photocells Press Clear to reset photocells Ke SERVICE TESTS 1 1 FU SERVICE TESTS 2 Photocell condition 2 Digital inputs 3 DFC test 4 Actuator tests 5 6 figure 3 17 The two menu screens for the FV SERVICE TESTS The me
17. 6 7 8 9 71 Message Technical failure Action Call service Info Power failure The 12 V power supply voltage in feeder unit x x 1 3 is too high 5 4 Other FPI 5000 C feeder unit related diagnostic information e A flashing green LED D102 on 5000 base unit board 97 50 10 indicates correct operation of the local 97 50 12 software The normal flashing frequency is about 1 Hz If an error occurs the flashing frequency is about 4 Hz The green LED D502 on the FPI 5000 C base unit board 97 50 10 indicates the presence of the 5 V power supply VCC and AVCC The green LED D301 on the FPI 5000 C base unit board 97 50 10 reflects the state of the slotted photocell VSPH2 TPID See also the BM digital inputs menu of section 3 3 3 e The green LED D302 on the 5000 base unit board 97 50 10 reflects the state of the slotted photocell VSPH3 TP2D See also the BM digital inputs menu of section 3 3 3 e The green LED D304 on the 5000 base unit board 97 50 10 reflects the state of the slotted photocell VSPH5 TPAD See also the BM digital inputs menu of section 3 3 3 e The green LED D305 on the 5000 C base unit board 97 50 10 reflects the state of the slotted photocell VSPHI TP5D See also the BM digital inputs menu of section 3 3 3 510 03 76 rev 01 0 01 2002 service manual FPI 5000 I e The green LED D306 on 5000 base unit board 97 50 10 reflects the state o
18. General note This document describes the inserter FPI 5000 I the 110 V 60 Hz version the 230 V 50 Hz version and the 100 V 50 Hz version 510 00 6 rev 01 0 01 2002 2 Specifications 2 1 Machine specifications Model Overall Dimensions height width length Weight Noise level Theoretical max speed Operating temperature Humidity Power consumption Approvals rev 01 0 01 2002 service manual FPI 5000 I FPI 5000 I inserter module for medium office use 405 mm 15 9 inch 455 mm 17 9 inch with side catch tray depends on envelope size 650 mm 25 6 inch conveyor 1050 mm 41 3 inch side exit 780 mm 30 7 inch catch tray depends on envelope size approx 48 kg 105 8 Ibs lt 70 dB A following DIN 45635 part 19 3500 inserts p h depending on configuration 10 40 C 50 104 F 10 80 100 120V AC 50 60Hz 3 Amps 220 240V AC 50Hz 1 4 1 5 Amps conforms to IEC 950 and derivatives UL listed ITE File E153801 BS EN60950 File KM11322 510 00 7 service manual FPI 5000 I 2 2 Envelope and paper insert specifications Maximum insert specifications are based on single sheets When multiples are handled more room inside the envelope is needed depending on application figure 2 1 Zee Booklets up to approximately 2 mm 0 08 inch thickness depending on stiffness When insert 15 more than mm thickness 15 mm A 0 6
19. Remove the RH side cover as described in paragraph 1 3 RH side cover Open the LH hinged side cover as described in 1 4 LH hinged side cover 8 1 Sealing rollers Upper sealing roller Removal Refer to figure 8 1 Remove the spring clip 16 and slide the gear 15 off the sealing roller 6 Remove the pressure springs 13 from both sides of the sealing roller Remove the spring clip 1 and the spacer 2 Push the bearing 3 together with the sealing roller in the right hand side direction spring loaded until they both clear the LH inside frame 28 Tilt the left hand side of the sealing roller upwards and when possible remove the bearing 3 the washer 4 and the pressure spring 5 and withdraw the sealing roller in the left hand side direction Lower sealing roller Removal Remove the upper sealing roller as described previously Remove the long chain as described in paragraph 3 1 2 Long chain Refer to figure 8 1 Remove the spring clip 24 and slide the gear 23 off the axle Tap out the tension pin 17 and slide the sprocket 18 off the sealing roller 7 Remove the washer 19 and the spacer 20 and slide the gear 21 off the sealing roller Remove the two round head screws 14 securing the ball bearing 12 Take care of the locking plate 11 Remove the spring clip 27 the spacer 26 and the bearing 25 Tilt the right hand side of the sealing roller in the rear side direction and when possible shift it in the right hand side direction unt
20. x 10 05 38 74 2 6 Mounting pin 43 61 75 2 7 Guide plate 23 22 93 1 8 Inside frame LH 95 73 09 1 9 Bracket 95 71 35 1 10 Flagswitch 02 10 76 1 11 Nut M4 45 19 02 1 12 Holder 98 00 20 1 13 Protecting plate 95 73 13 1 14 Cover 95 71 52 1 15 Frame axle 95 71 53 2 16 Side guide RH 95 71 15 1 17 Front plate 95 71 07 1 18 Side guide LH 95 71 18 1 19 Adj nut 95 71 20 2 20 Round head screw MA x 4 45 43 10 6 21 Adj axle 95 71 12 1 22 Fixing plate axle 95 71 26 1 23 Thumb wheel 24 13 58 1 24 Envelope support assy 95 74 01 1 25 Feeding table assy 95 71 23 1 26 Washer 12x 94 3 x 1 mm 45 37 43 2 27 Crinckle washer 05 24 84 4 28 Washer 9 x 4 3 x 0 8 mm 45 37 02 4 29 Nut M4 self locking 05 36 21 2 30 Bottom cover 95 71 25 1 31 Countersunk head screw M4 x 10 45 38 75 6 32 Locking spring 03 63 36 2 33 Spring clip 9 12 mm 05 24 55 1 34 Washer 16 x 10 2 x 0 8 mm 04 01 43 1 35 Separation axle 95 71 05 1 36 Separation roller assy 95 71 03 1 37 Setscrew M4 x 4 08 28 01 2 38 Round head screw MA x 8 05 38 68 4 39 Guide axle 95 71 11 2 40 Hex head screw MA x 8 05 38 80 2 4 Round head screw M4 x 6 05 38 66 6 42 Round head screw M4 x 30 45 43 19 1 43 M4 half d 45 19 19 1 44 Spring clip 7 9 mm 05 24 42 2 45 Adj nut 95 71 34 1 rev 02 0 02 2002 510 04 21 Figure 510 04 20 Remarks 510 04 22 illustration code number 46 47 48 49 service manual Description Separation slide Ro
21. 45 38 69 45 37 45 97 01 11 95 73 83 05 38 80 95 73 80 95 73 57 45 37 43 05 24 84 05 36 21 BR OR N e 510 04 57 service manual FPI 5000 I 510 04 58 rev 02 0 02 2002 service manual FPI 5000 I Stacker Part number 95 73 51 rev 02 0 02 2002 510 04 59 FPI 5000 I service manual 04 12 Figure 16 rev 02 0 02 2002 510 04 60 service manual FPI 5000 I Figure 510 04 60 Remarks illustration Description Part code Quantity Remarks code number number FPI 5000 I Roller 95 71 61 1 2 Round head screw M3 x 6 45 43 02 3 3 Washer 7 x 03 2x 0 5 mm 45 37 39 2 4 Paper guide 95 71 70 1 5 Fixing axle 95 71 69 1 6 Spring clip 5 7 mm 05 24 66 1 7 Pressure spring 95 71 64 4 8 Washer 9 x 4 3 x 0 8 mm 45 37 45 7 9 Round head screw MA x 25 05 38 72 4 10 Frame 95 71 51 1 1 Belt 96 10 00 2 12 Setscrew MA x 4 08 28 01 2 13 Round head screw x 8 mm 05 38 68 2 14 _ Suspension frame for drive axle 95 71 54 1 15 26 06 12 2 16 Drive axle 95 71 63 1 17 Spring clip 9 12 mm 05 24 55 4 18 Washer 16 x 10 2 x 0 8 mm 04 01 43 4 19 Bearing POM IO mm 04 24 26 2 20 Countersunk head screw M4 x 10 45 38 75 2 2 Fork assy 74 17 02 2 22 Washer 14 x 8 2 x 0 8 mm 04 01 41 2 23 Spring clip 7 9 mm 05 24 42 1 24 Stacker frame assy 95 71 56 1 25 Roller incl freewheel clutch 95 71 60 1 26 Nut M4 45 19 02 3 27 Suspension frame 95 71 57 1 28 Axle 95 7
22. After removing the two round head screws 5 with the washers 4 and spacers 3 the microswitch 1 can be removed and disconnected Take care of the insulating plates 2 on both sides of the microswitch rev 01 0 01 2002 510 02 63 service manual FPI 5000 I 9 1 3 Flag switch Removal Remove the rear cover as described in paragraph 1 14 Rear cover figure 9 3 Refer to figure 9 3 Remove the nut 1 securing the bracket 2 with the flag switch 3 to the envelope guide 4 From the insert area push the switch lever in the rear side direction as far as possible and hold it Push the lower left hand end of the bracket in the right hand side direction tilt it and then withdraw it Take care of the wiring Disconnect the flag switch and remove it from the bracket Replacement Ensure on replacement that the topside of the bracket retains the wiring of the flag switch 510 02 64 rev 01 0 01 2002 service manual FPI 5000 I 92 Pulse disc detector Removal Remove the RH s de cover as described n paragraph 1 3 RH s de cover figure 9 4 Refer to figure 9 4 Remove the countersunk screw 6 securing the pulse disc 4 Remove the pulse disc together with the two spacers 5 Cut the wire strap securing the wiring to the bracket 1 and disconnect the pulse disc detector 2 Remove the two round head screws 3 with washers and withdraw the pulse disc detector Replacement Ensure on replacement that the pulse disc detector cle
23. Folder 2 4 4 Offset 5 Save and exit 6 figure 3 15 The FOLDER OFFSET menu 3 32 The FV CONFIG SETTINGS menu The presence of the divert unit the feeder unit s and the DFC units is recorded in non volatile FRAM on the FRAM board 95 74 55 of the FPI 5000 I The FRAM 15 automatically updated if a component has been added but will not be automatically updated if a component appears to be deleted The jumper settings on the feeder board s 93 08 02 are not stored in FRAM but read at the start of each machine session The system settings menu of figure 3 16 shows the configuration as based on the FRAM settings If you delete a component the machine issues an error during the next startup The error message 15 related to the deleted item If a component has been accidentally deleted during certain service actions of the machine the error message suggests you to mechanically and electronically restore this component and restart the machine However if a component is intentionally deleted the machine configuration must be updated 1 the deleted component s must be 510 03 38 rev 01 0 01 2002 service manual FPI 5000 I deleted from FRAM as well If you press the Reset configuration key you will get the message Restart system to set new configuration Switch the machine off and on again Now the FRAM will be updated The bottom line 1s that this menu is used to reset error messages that are related to intentionally deleted
24. none During the process the photodiode of photocell PH3 is readjusted at a too low current resulting in a too sensitive photocell This message may be issued during factory production testing only or after field replacement of the photocell The photocell must be replaced by a less sensitive photocell Error 1 51 Message Exit sensor dusty Action Clean sensor rev 01 0 01 2002 510 03 59 service manual FPI 5000 I Info none During the process the photodiode of photocell PH4 is readjusted at a too low current resulting in a too sensitive photocell This message may be issued during factory production testing only or after field replacement of the photocell The photocell must be replaced by a less sensitive photocell Error 1 52 Message Technical failure Action Call service Info Track sensor defective The no paper output voltage of photocell PH1 cannot be set on a value between 0 7 V and 1 3 V This message may occur during the photocell adjustment at the very first start of the machine or during a startup with FRAM reading errors or during the photocell test This is most likely caused by paper being present under the photocell Error 1 53 Message Technical failure Action Call service Info Flap sensor defective The no paper output voltage of photocell PH2 cannot be set on a value between 0 7 V and 1 3 V This message may occur during the photocell adjustment at the very first start of the machine or du
25. 0 10 4 x 5 mm Ejection axle Pulley 14T Timing belt Tension pin 2 5 x 20 Axle Pulley 16T Gear 15T FPI 5000 I Part code Quantity Remarks number FPI 5000 I 23 26 00 04 08 37 43 28 75 06 04 45 04 15 37 om om 05 33 24 43 29 01 06 04 44 24 08 57 9 02 0 02 2002 service manual FPI 5000 I Side exit Part number 97 01 52 rev 02 0 02 2002 510 04 53 service manual FPI 5000 I 41 40 39 38 37 36 35 ONE RO 29 30 31 M0 i M P 15 14 13 Figure 14 510 04 54 rev 02 0 02 2002 service manual FPI 5000 I Figure 510 04 54 Remarks illustration Description Part code Quantity Remarks code number number FPI 5000 I Socket head screw M5 x10 05 28 50 2 2 Transparent cover 95 73 93 1 Nut M4 half d 45 19 19 2 4 Transportation table 97 01 10 1 gt Pulley 95 73 74 2 6 Belt 95 73 78 2 7 Setscrew x 4 08 28 01 2 8 Drive axle 97 01 01 1 9 Tension pin 2 5 x 16 05 33 22 1 10 Gear 15T 24 08 57 1 11 Washer 16 x 10 2 x 0 8 mm 04 01 43 4 12 Conductive bearing 10 mm 04 24 26 2 13 Bearing bush 95 73 65 1 14 Gear 18T 95 73 76 1 15 Countersunk head screw M4 x 10 45 42 13 1 16 Stop stud 45 38 71 2 17 Knurled nut 02 11 25 1 18 Round head screw x 16 97 01 14 1 19 Bottom plate 95 73 90 1 20 Self sticking plug 95 90 35 2 21 Nut M4 45 19 02 11 22 Washer 9 x 04 3 x 0 8 mm 45 37 45 9 23 Frame 95 7
26. 014 lt 1NOGNI ZN3S 1 Mano i 33 ALZAS 8110 ezres n on i 0214 1 DOA OL i i ZZ8SNL do i oora 7 eola voranz i mm 2 EBD 0011 0914 AU noms N NOOL NOOL 3100 7 qe 2912 0510 403344 H pa ve sa i 00Z rarnay wwog ys dW 19917 DIN id 9 s 89 NOOL oni 0 0 2 yuIsyeoy 001 gt 4 WAIN 069 NL WAIN A0 9 NL xz 870 679 NOLSW4 power supply 1 ICS board 94 80 01 electroni in Ma figure 1 4 510 03 15 rev 01 0 01 2002 SA IMS00 service manua HOLNI LYOdSNVUL 3dO13AN3 X4201 ZHd XL LHd XLAN3 VLOHYL VLOHYL x add NOL 30221 09241 2720 SZ _ NOOL MOOL erzo 7 240 Tega 4 VLOHYL 9 aozzn 2 lt 8 139835079 512 jesyo 94G V SSANMOIHL 8 149445019 ren 00L oszr VLOHYL gozzn yos uiid aasn on an9 NOOL 02209 2 JOA 0V14 25070 VLOHYL 2022n
27. 1 Loc Remove the sprocket 18T item 13 as described in paragraph 3 5 2 Sprockets long chain Removal Refer to figure 3 2 Remove the countersunk screw 17 securing the pulse disc 15 Remove the pulse disc together with the two spacers 16 Take care of the pulse disc detector 8 Refer to figure 3 3 Hold the bearing plate 15 and remove the three countersunk screws 1 spring loaded securing it Carefully place the bearing plate aside Take care of the pulse disc detector 13 the bearing 14 and the washer 16 Slide the pressure spring 17 and the washer 18 off the axle Remove the spring clip 19 Slide the gear 20 off the axle rev 01 0 01 2002 510 02 25 service manual FPI 5000 I Gear 35T item 7 Removal Remove the front cover as described n paragraph 1 11 Front cover Release the chain tensioner 20 as described in paragraph 3 1 1 Short chain Release the chain tensioner 1 as described n paragraph 3 1 2 Long chain figure 3 4 Refer to figure 3 4 Remove the fixing screw 1 Take care of the fixing ring 2 Remove the two round head screws 11 securing the ball bearing 10 Shift the axle 9 the right hand side direction until it is clear from the LH inside frame Slide the washer 3 the spacer 4 and the gear cover 5 off the axle Remove the spring clip 6 and slide the gear 7 off the axle Take care of the cyl pin 8 Adjustment See paragraph 10 1 Short chain See paragraph 10 2 Long chain
28. 2 70 Message Sensor dusty Action Clean sensor Info none The relevant photocell VPH4 output of folding subsystem is dusty to such an extent that the full 10096 of the photodiode current has been reached Readjust the photocell after cleaning with no paper present Error 2 71 Message Technical failure Action Call service Info Sensor fold out defective 510 03 66 rev 01 0 01 2002 service manual FPI 5000 I The photocell transmitter receiver combination of photocell VPH4 15 defective Check the wiring of both photocell parts Error 2 72 Message Technical failure Action Call service Info Sensor fold out defective The photocell transmitter LED of photocell VPH4 s defective Check the wiring Error 2 73 Message Sensor dusty Action Clean sensor Info none Sensor needs readjustment after removed dust causes a too high LED current setting of the relevant photodiode Error 2 75 Message Sensor dusty Action Clean sensor Info none The relevant photocell VPH4 output of folding subsystem is dusty to such an extend that at least 80 of the photodiode current has been reached Compared with error 2 70 there is still a certain dust margin Readjust the photocell after cleaning with no paper present 5 3 2 Vertical transport subsystem Error 3 00 Message Empty feeders Action Load documents Info This error appears when all feeders found empty during Fill amp Start initialis
29. 4 from the axle Take care of the cyl pin 7 and the gear 1 Replacement Ensure on replacement that the two rollers are refitted correctly on the axle narrowing part of both rollers pointing inwards and the set screws rest into the grooves in the axle Second set of transportation rollers 30 mm Removal Refer to figure 4 2 Remove the clamping ring 8 and washer 9 Slide the gear 12 off the bearing pin Take care of the two spacers 14 and 15 Push the rear side of the flap guide 35 from the frame rod 36 and then pull it in the rear side direction from the frame rod 34 Push the left hand transportation roller 6 inwards from the cyl pin 5 Remove the cyl pin from the clutch shaft 33 Slide the left hand transportation roller off the clutch shaft Push the right hand transportation roller 31 inwards from the cyl pin 32 Remove the cyl pin from the clutch shaft Remove the spring clip 30 Remove the spring clip 23 the spacer 22 the washer 21 and the bearing 18 Slide the clutch shaft in the left hand side direction Take care of the washer 17 Remove the freewheel clutch assembly 24 25 26 and 27 the spacer 28 the washer 29 and the right hand transportation roller from the clutch shaft rev 01 0 01 2002 510 02 31 FPI 5000 I service manua EZ S6 90 C figure 4 3 rev 01 0 01 2002 510 02 32 service manual FPI 5000 I Third set of transportation rollers 30 mm Removal Refer to figu
30. 5000 I 2 Electrical components Warning Beware of possible electrostatic discharge 2 1 Power supply unit Removal Remove the electronics cover as described in paragraph 1 5 Electronics cover Remove the power supply cover as described in paragraph 1 8 Power supply cover Refer to figure 2 1 Cut the wire strap securing wiring to the electronics plate 17 Disconnect the wiring of the power supply unit 4 at the mainboard 15 Disconnect the motor wiring from the terminal block 1 on the power supply unit Remove the three hex head screws 2 securing the power supply unit to the LH inside frame 5 Take care of the crinkled washer 3 Withdraw the complete power supply unit assembly in the left hand side direction from the machine 2 2 Mainboard and FRAM PCB Removal Remove the electronics cover as described in paragraph 1 5 Electronics cover Refer to figure 2 1 Disconnect all the wiring connected to the mainboard 15 Carefully pull the FRAM PCB 6 from the four PCB holders 19 Remove the round head screw 13 with the crinkled washer 14 Take care off the spacer 18 Carefully pull the mainboard 15 from the five PCB holders 16 and withdraw it 2 3 Control panel Removal Remove the electronics cover as described in paragraph 1 5 Electronics cover Refer to figure 2 1 Remove the four selflocking nuts 7 Lift the control panel 8 upwards and withdraw it Take care of the two spacers 9 fitted on the all four studs 12 and t
31. 5000 I Figure 510 04 6 illustration Remarks code number Remarks Description Part code Quantity number FPI 5000 I rev 02 0 02 2002 Mi RP V DV WON DN 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 33 34 35 36 37 38 39 Envelope tray assy Slide complete Bellows Cover Cover plate Round head screw MA x 8 Cover Distance pin Nut M4 Cover assy Cover RH Cover plate Mounting bracket Cover plate Guide bracket Guide spring long Countersunk screw M4 x 16 Dust cover Main lead 220V Main lead 110V Bottom plate Hex head screw M4 x 12 Connecting lead Cover power unit Mounting plate Countersunk screw M4 x 8 Lock washer 5 32 Cap Nut 4 Slide frame Strip Washer 9 x 4 3 x 0 8 mm Mounting plate Mounting bracket Cover LH Water tank Grommet Moistening cloth Holder Cover Cover 97 01 04 04 23 20 04 13 04 98 00 42 98 00 26 45 38 68 98 00 10 98 00 29 45 19 02 98 00 01 98 00 07 36 04 49 98 00 21 98 00 09 36 07 14 73 53 98 45 38 77 93 06 90 12 15 08 12 15 07 95 73 01 05 38 80 02 14 97 95 70 55 98 00 15 45 42 12 05 24 31 45 36 26 95 71 61 97 00 51 45 37 02 98 00 16 98 00 19 98 00 36 04 11 68 12 08 51 04 03 06 98 00 20 98 00 41 95 70 78 m UC WN CO N e SS ON SS me e N
32. 95 73 15 43 26 24 05 38 82 05 24 68 02 10 21 45 37 43 45 12 38 13 28 93 83 01 16 43 31 93 05 33 24 04 23 19 43 42 59 95 73 02 04 11 95 12 12 22 45 38 67 OQ ha N e m DHD rev 02 0 02 2002 service manual FPI 5000 I rev 02 0 02 2002 510 04 31 service manual FPI 5000 I LAWS lt SED oS gt O Q G 23 149 8 O 5 QS 1155 AQA 47 21 26 25 31 5 30 29 5 28 Figure 8 510 04 32 02 0 02 2002 service manual FPI 5000 I Figure 510 04 32 illustration Remarks code number Remarks Description Part code Quantity number FPI 5000 I rev 02 0 02 2002 gt V oO SO DN m 11 13 14 15 16 17 18 19 20 21 22 23 24 23 26 21 28 29 30 31 22 Spacer 15 x 10 4 x 3 mm Washer 16 x 10 2 x 0 8 mm Sprocket 18T Tension pin 2 5 x 20 Sprocket 15T Clamping disc Pulse disc Washer 20 x 6 2 x 2 mm Countersunk head screw M4 x 10 Washer 14 x 8 2 x 0 8 mm Spring clip 10 14 mm Sprocket 15T Self lubricating bearing Self locking clip Main pulley Key Pulley assy Sprocket 15T Spring clip 7 9 mm Spacer 18 x 12 8 x 3 mm Cyl pin 2 5 x 12 Clutch CW clockwise 8 mm Sprocket 22T Chain 115 links Drive belt PJ L 813
33. After pressing one of these keys the relevant cam disc will move one half cycle 1 the cam disc status changes from open to covered or from covered to open After pressing two successive times on a test key the cam disc has performed a full cycle and returns to its position prior to entering this menu If the Test both key 1s pressed both cam discs will move one half cycle In a future service software release a test routine will be built in to dynamically test the pulse discs The indented areas of the pulse discs should be free of any production residue which is thoroughly checked for in the factory or dust particles which may occur during operational use Short explanation of the various digital inputs In order to analyse the results of the digital inputs tests it is relevant to give in this context some additional information on the various digital inputs The central pulse disk is mounted is present at the RH side of the machine It is mounted on the input axle to which the mechanical drive from the FPI 5000 I is transferred This pulse disk is monitored by the slotted photocell VSPHI The information from VSPHI is used for the timing of all document related processes in the FPI 5000 C The state of VSPHI is reflected by LED D305 on the FPI 5000 C board 97 50 10 The collator pulse disc is mounted on the collator motor VM1 Its movement is monitored by the slotted photocell VSPH4 The state of VSPHA is reflected by LED D306 on
34. DIGITAL IHPUTS MS2 MS 51 VMS2 Main pulse disc Open Loc Closed Front Closed Extern Closed Seal switch Closed OU WN o gt figure 3 8 The menu IN DIGITAL INPUTS 32 2 The menu DFC The DFC screen of figure 3 9 shows the real time DFC output voltage expressed in millivolt If you place paper at the DFC sensor or manually move the DFC sensor this is reflected by an increase in the measured and displayed DFC output voltage The DFC output voltage varies according to the rule of a voltage increase of 1000 mV per millimeter measured thickness If the DFC sensor is manually pushed in to its mechanical limit the measured DFC output voltage has a value between 4000 and 5000 mV If no paper is present 1 e with a zero thickness the measured DFC output voltage lies between 250 mV and 750 mV So the DFC output voltage is not zero This preset voltage 1s applied to the DFC sensor electronics in order to ensure that only the linear operating range 1 e 1000 mV per mm measured thickness of the DFC sensor is used DFC OU WN figure 3 9 The output voltage menu 510 03 34 rev 01 0 01 2002 service manual FPI 5000 I 32 3 The menu ACTUATORS In this menu see figure 3 10 the correct operation of the four actuators of the FPI 5000 I can be verified If the test key is pressed the selected actuator will be activated The motor runs as long as the test key is p
35. FPI 5000 I The JOB SETTINGS menu of figure 3 28 consists of the following three menus System output figure 3 29 Paper stop figure 3 30 Document offset figure 3 31 Secure jobs figure 3 32 BRE offset figure 3 33 JOB SETTIHGS System output OMR code definition Paper stop Document offzet Secure jobs BRE Offset figure 3 28 The menu JOB SETTINGS The SYSTEM OUTPUT menu In this menu see figure 3 29 for each of the jobs through 9 a choice can be made between the operating mode Mode 1 and the operating mode Mode 2 Mode 2 1s the default setting Mode 1 focuses on the versatility of paper parameters paper thickness document length i e correct operation under even extreme paper conditions Mode 2 focuses on high speed The differences between the two modes are related to the way in which the documents of a set are collated It is advised to use Mode 1 with a paper thickness of 65 g m or less a document length of 12 inch or higher and for some unusual customer specific applications In all other cases Mode 2 is advised Background information In the Mode 2 case the paper transport stops as soon as the document that is to be added to the set has entered the collating area this is detected by the collator entry photocell The partially completed set is moved to the fold table during a short distance This distance is sufficient to prevent the leading edge of the next entering document from
36. Pulley 50 Hz Pulley 60 Hz Set screw MA x 10 Sprocket 15T Gear 15T Chain 266 links Spacer 17 x 10 2 x 2 mm Cyl pin 2 5 x 32 04 08 58 04 01 43 04 23 23 05 33 24 23 68 86 43 30 46 24 12 81 43 07 90 45 38 75 04 01 41 05 24 83 73 17 99 06 09 17 05 26 00 26 05 15 05 25 50 76 05 14 03 28 57 05 24 42 04 08 71 05 23 47 12 14 63 43 50 53 04 15 32 04 15 57 26 05 10 26 05 11 08 28 05 73 54 29 24 08 57 04 15 38 04 10 94 05 23 48 e me We N 49 tA mm N me tA tA Ww Ln m 510 04 33 FPI 5000 I service manua 85 6S 09 19 49 49 65 7 I Figure 9 rev 02 0 02 2002 510 04 34 service manual FPI 5000 I Figure 510 04 34 Part code Quantity Remarks number FPI 5000 I illustration code number Remarks Description rev 02 0 02 2002 Mi RP So m 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Washer 0 14 x 8 2 x 0 8 mm Spring clip 7 9 mm Washer 14 x 07 4 x 1 6 mm Spring clip 6 8 mm Brake rod Spacer 12 x 8 3 x 3 mm Gear 17T Gear 15T Tension pin 2 5 x 16 Gear 15 Clutch shaft assy Transportation roller 31 7 mm Set screw M4 x 4 Cyl pin 2 5 x 16 Transportation axle Transportation roller 30 mm Transportation roller 30 mm Air
37. Removal Refer to figure 6 2 Remove the spring clips 24 the washers 23 and the bearings 22 from both sides of the drive axle 21 Remove the front drive axle assembly from between the loc frame 18 Slacken the two set screws of the bushing 9 Push the bearings 2 and 12 out of the slotted holes in the loc frame and the cross bar Withdraw the rear drive axle assembly together with the main drive belt 6 from the loc frame Remove the main drive belt from the rear drive axle assembly Replacement Ensure on replacement that there is no axial play on the drive axle 7 after securing the bushing 9 and check on replacement of the cover plate that both rollers 1 and 8 protrude through the respective apertures in the cover plate without touching the plate Adjust the position of the rollers 1f necessary 510 02 46 rev 01 0 01 2002 service manual FPI 5000 I 24 23 22 figure 6 2 6 2 2 Pulleys Pulley 16T item 20 Removal Remove the front drive axle assembly as described in the previous paragraph Refer to figure 6 2 Tap out the tension pin 14 Slide the pulley 20 off the drive axle 21 rev 01 0 01 2002 510 02 47 service manual FPI 5000 I Pulley 14T item 5 Removal Remove the main drive belt as described in the previous paragraph Refer to figure 6 2 Slacken the set screw of the roller 1 and slide it off the drive axle 7 Remove the bearing 2 the washer 3 and the spacer 4 Tap out the tension pin securing the
38. The envelope then passes the flap rollers The combined action of the flap scraper and the lower linear speed of the flap rollers compared with the speed of the third envelope transport rollers results in some buckling and the opening of the envelope The flap 1s the trailing part of the envelope passing the flap rollers and the flap detector PH2 Pulse measurements by pulse disc PD1 during the presence of the envelope under and PH2 provide information on a the length of the not yet opened envelope b the opened envelope and c the time at which the envelope transport is suddenly stopped with the envelope on the insert table The sudden stop is the result of disengaging by RPMI and the friction brake The envelope flap now is fixed between the flap holder rollers 2 2 Document input and insert Once the envelope is on the insert table the fingers solenoid Sol is activated Five fingers are moved forward into the envelope This is necessary to insert the document set in the envelope The FPI 5000 I now orders the FPI 5000 C feed the document or document set to be inserted This document set passes a three pairs of document rollers b the DFC unit for a thickness check the insert rollers d document detector PH3 and e the fingers before entering the envelope 2 3 Envelope ejecting sealing and exiting rev 01 0 01 2002 510 01 7 service manual FPI 5000 I The insert is considered finished if and whe
39. and the jogger are tightened onto the flattened part of the feed shaft Adjustment See paragraph 10 6 Joggers 4 1 3 Gear Gear 28T item 10 Removal Remove the feed shaft as described in paragraph 4 1 1 O rings Refer to figure 4 1 Remove the spacer 9 and slide the gear 10 off the feed shaft 15 rev 01 0 01 2002 510 02 29 0 c0 0IS COOC TO Q0 10 91 cr o1nog B D 19 20 23 0 a 22 P gt LA 21 14151617 18 x N k a Z O N er 9101112 13 SEB Sp R 2 LN 97 2 5 fem 9014195 I 0008 Idi service manual FPI 5000 I 4 2 Envelope track 4 2 1 Rollers Remove the RH s de cover as described n paragraph 1 3 RH side covers Remove the LH hinged side cover as described in paragraph 1 4 LH hinged side cover Remove the base cover as described in paragraph 1 9 Base cover First set of transportation rollers 36 mm Removal Refer to figure 4 1 Remove the two round head screws 2 and withdraw the gear cover 7 Remove the two round head screws 19 and withdraw the gear cover 18 Refer to figure 4 2 Slacken the set screws of the two transportation rollers 4 on the axle 3 Remove the spring clip 2 securing the gear 1 Remove the spring clip 20 the washer 19 and the bearing 16 Slide the axle in the left hand side direction and remove the spacer 13 the gear 11 the slip clutch 10 and the two transportation rollers
40. be verified During the pressing of a key the corresponding key number is displayed as follows Sof key 1 Soft key 2 Soft key 3 Soft key 4 Soft key 5 Soft key 6 Escape key white Clear key white Stop key red Start key green table 3 1 If two or more keys are pressed simultaneously a value is displayed that reflects the addition of the individual key values You only can leave this menu by pressing the Escape key twice without pressing any other key between the Escape key presses Key KETBOARD Exit 2 esc JP228 JP225 O U AK U figure 3 12 The menu KEYBOARD 3 2 6 The menu Reset Data There may be situations 1 which it s necessary to restore the machine settings to their states at the beginning of the machine s operational life To this purpose the menu item Reset Data of figure 3 13 is present It is advised to remove all paper from the machine This is necessary because the data resetting includes removing certain hardware settings for paper photocells so these photocells will be readjusted as well You can leave this menu by pressing the Escape key Press key 5 to start the data reset operation This involves clearing all the data in the non volatile FRAM memory on the FRAM board 95 74 55 of the FPI 5000 I Subsequently this memory is loaded with default data consistent with the virgin state of the machine leaving the factory including nine default jobs Note I The changes made by this res
41. interrupts or blocks the motor relay current This happens irrespective of the status of the CPU motor drive signal The motor stops immediately or doesn t start at all Thus no possibly unsafe human contact with moving parts 1s possible As a consequence the mechanically FPI 5000 I driven FPI 5000 C are stopped as well or not driven at all System connections The 12 pole upstream system connector see figure 1 2 is connected with J500 of the main board See figure 1 8 for details This system connector is wired according to the SCS specification As the FPI 5000 I s dedicated to cooperation with the FPI 5000 C and its attached feeder units the combination being known as the SA 5005 feeding folding and inserting system the communication between these two parts must address the fact that the FPI 5000 C part of the SA 5005 doesn t have its own user interface Therefore all FPI 5000 C related messages must be communicated to the FPI 5000 I To this purpose the PC communications protocol has been enhanced with a message software layer Clutch and solenoids Clutch is mounted on a driven flap roller Two coaxial axles are coupled by driving a DC current through a coil electromechanical action One axle the outer one is coupled with the main drive The inner axle is connected with the subsystem for the empty envelope transport The solenoids are based on electromechanical action as well The CPU via buffers supplies the signals for the a
42. the two gears 25 and 26 of the freewheel clutch 27 Gear 35T item 9 Removal Refer to figure 4 3 Remove the clamping ring 7 and the washer 8 Slide the gear 9 off the bearing pin Take care of the spacer 11 Gear 15T item 17 Removal Withdraw the axle as described in paragraph 4 2 1 Third set of transportation rollers 30 mm Refer to figure 4 3 Tap out the tension pin 10 Slide the gear 17 off the axle 18 Gear 28T item 3 Removal Refer to figure 4 4 Remove the two hex head screws 2 and securing the flapscraper 3 to the envelope guide 16 Withdraw the flapscraper Remove the four round head screws 1 securing the envelope guide to both inside frames Refer to figure 4 5 Pull the envelope guide aside so it is clear from the gear 3 Remove the clamping ring 1 and the washer 2 Slide the gear off the bearing pin Take care of the spacer 7 Adjustment See paragraph 10 9 510 02 36 rev 01 0 01 2002 service manual FPI 5000 I a x 2 N NE GS Y N D V X o C VS 7 Bm gt 012 3456789 N NK 73 NS NS S MEER Wea nt 4 NN Q figure 4 5 rev 01 0 01 2002 510 02 37 service manual FPI 5000 I Gear 17T item 5 Removal Withdraw the rubber roller as described in paragraph 4 2 1 Rubber roller 31 7 mm Refer to figure 4 5 Tap out the tension p
43. the washer 26 rev 01 0 01 2002 510 02 33 service manual FPI 5000 I Rubber roller 31 7 mm Remove the cover plate as described in paragraph 1 6 Cover plate Remove the transportation table as described in paragraph 1 10 Transportation table Remove the insert table as described in paragraph 1 12 Insert table 12 13 14 15 figure 4 4 Removal Refer to figure 4 4 Remove the spring clip 15 Slide the gear 13 off the rubber roller axle 7 Remove the spring clip 6 Slide the rubber roller in the left hand side direction until it clears the RH inside frame 12 Lift the right hand side of the rubber roller upwards take care of the fingers and when possible withdraw it in the left hand direction from the machine Take care of the bearing 4 and the washer 5 510 02 34 rev 01 0 01 2002 service manual FPI 5000 I 4 2 0 Gears Remove the RH s de cover as described n paragraph 1 3 RH side covers Remove the LH hinged side cover as described in paragraph 1 4 LH hinged side cover Remove the base cover as described n paragraph 1 9 Base cover Gear 15T item 3 Removal Refer to figure 4 1 Remove the two round head screws 2 and withdraw the gear cover 7 Refer to 4 3 Remove the spring clip 5 and the spacer 4 Slide the gear 3 off the bearing pin Take care of the washer 2 and the spacer 1 Gear 28T item 11 Removal Refer to figure 4 1 Remove the two round head screws 2 and withdraw the gea
44. upper reverse roller is lowered to start the sealing After the passing of the envelope the pawl returns to its rest position by spring action Two micro switches 51 at the side cover and M52 at the top cover stop the motor if one or both covers opened An unsafe micro switch directly interrupts the current through the motor relay and stops the motor immediately DFC unit Double Feed Control is the name usually used for describing a sensor which in fact is a thickness measuring unit It is an analogue measurement of the thickness of the passing document set The DFC unit is located at the second pair of document input rollers In this way the measurement is done at a place where the document set 1s pressed The DFC unit consists of a Hall sensor located between two permanent magnets Via various mechanical devices a document thickness of maximally 4 mm is translated in a proportional DC output voltage The output of the Hall sensor is amplified and factory set at a conversion rate of 1 volt per mm thickness The DFC output is fed to an ADC channel of the CPU Comparing this input data with reference data may result in an error message For reasons of operational performance a DAC supplied reference voltage is fed to the differential amplifier on the small printed circuit board of the DFC unit The rev 01 0 01 2002 510 03 9 service manual FPI 5000 I figure 1 18 shows the circuit diagram of the local DFC electronics This volt
45. 000 I 7 Envelope transport 71 Lower ejection rollers Remove insert table as described in paragraph 1 12 Insert table First set of lower ejection rollers 30 mm Removal Remove the main drive belt as described in paragraph 3 3 Main drive belt Refer to figure 7 1 Remove the spring clip 9 Slide the gear 10 off the axle 13 Remove the two round head screws 11 securing the ball bearing 12 Remove the spring clips 16 from both sides of the two ejection rollers 15 Remove the spring clip 17 Withdraw the ejection axle 14 in the right hand side direction out of the machine and slide the two ejection rollers with washers off it the washers are fitted on both sides of the two ejection rollers Take care of the bearing 19 and the washer 18 Replacement Ensure on replacement that the two ejection rollers are refitted correctly on the ejection axle narrowing part of both rollers pointing inwards Second set of lower ejection rollers 30 mm Removal Remove the long chain as described in paragraph 3 1 2 Long chain Refer to figure 7 1 Push the two ejection rollers 27 in the right hand side direction from the cyl pins below Remove the two cyl pins from the ejection axle 26 Remove the spring clip 22 the washer 21 and the bearing 20 Withdraw the ejection axle in the right hand side direction out of the machine and slide the two ejection rollers off it Take care of the bearing 6 the washer 7 and the spacer 8 Rep
46. 000 I Figure 510 04 46 Part code Quantity Remarks number FPI 5000 I illustration code number Remarks Description rev 02 0 02 2002 V oo 1 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Transportation roller 38 mm Washer 16 x 0 10 2 x 0 8 mm Spacer 15 x 10 4 x 5 mm Pressure spring 1 mm Bearing plate Spacer 15 x 10 4 x 10 mm Gear 15T Gear 15T Rod Transportation axle Solenoid Clamping ring 3 mm Pressure spring Draw bar Bearing plate Spacer 15 x 10 4 x 7 5 mm Bearing plate Axle Tension pin 2 5 x 16 Gear 15 Gear 20T Nut M3 Washer 7 x 3 2 x 0 5 mm Tension spring 0 5 mm Bearing plate Round head screw M3 x 8 Washer 12 x 4 3 x 1 mm Guide Round head screw 4 x 10 Mounting clamp Clamping bracket Lock washer 5 32 Hinge axle Axle Damper Axle Set screw MA x 6 Locking spacer Clamping ring 6 mm Pressure spring 0 7 mm Conductive bearing 10 mm Spacer 15 x 10 4 x 3 mm Set screw M4 x 4 Transportation roller 42 5 mm Hex head screw M6 x 12 76 04 67 04 01 43 04 08 37 03 11 14 43 24 20 04 08 30 73 29 42 24 09 44 43 26 81 03 26 80 12 12 87 05 24 63 03 11 95 43 26 79 73 34 63 04 08 28 73 34 61 43 28 85 05 33 22 24 08 57 24 02 58 45 19 01 45 37 39 03 11 81 43 34 61 45 38 65 45 37 43
47. 04 10 18 05 38 69 12 14 89 12 14 06 05 24 31 43 30 95 43 26 62 03 11 90 43 26 63 08 28 30 95 72 61 05 24 58 03 11 11 04 24 26 04 08 58 08 28 01 73 25 76 05 38 85 NO N N N e N N e 9 uU m PO Ne 9 me BK WR N m NY c 510 04 47 Figure 510 04 47 Remarks illustration code number 46 47 48 510 04 48 service manual Description Spacer 8 x 4 3 x 10 mm Round head screw M4 x 8 Round head screw M4 x 16 Part code FPI 5000 I Quantity Remarks number FPI 5000 I 04 69 19 45 38 68 45 38 71 rev 02 0 02 2002 service manual FPI 5000 I rev 02 0 02 2002 510 04 49 FPI 5000 I service manua 16 15 14 13 12 11 4 7 2 7 Sa 24 23 22 21 45 46 47 48 49 50 N 42 43 44 Figure 13 rev 02 0 02 2002 510 04 50 service manual FPI 5000 I Figure 510 04 50 Description Part code Quantity Remarks number FPI 5000 I illustration code number Remarks rev 02 0 02 2002 Mi RP V oO SO DN m 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Bushing 16 x 8 x 8mm Gear 18T Tension pin 2 5 x 16 Bracket Led including holder Loc wiring Pan head tapping screw Round head screw M4 x 8 Wire strap holder Tension roller axl
48. 1 0 01 2002 service manual FPI 5000 I 9 4 Envelope and document detectors 9 4 1 Envelope detector Removal Transmitter LED Remove the base cover as described n paragraph 1 9 Base cover figure 9 6 Refer to figure 9 6 Pull the air hose from the transmitter 8 Cut all the wire straps securing wiring to the bracket 7 Remove the two hex head screws 1 securing the bracket Tilt the bracket and withdraw it in the front side direction Take care of the wiring Remove the pan head tapping screw 2 securing the transmitter to the bracket Withdraw and disconnect the transmitter Receiver Sensor Remove the insert table as described in paragraph 1 12 Insert table Refer to figure 9 6 Remove the nut 4 with the washer securing the bracket 6 Withdraw the bracket Take care of the wiring Cut the wire straps securing the wiring to the bracket Remove the pan head tapping screw 5 securing the receiver 3 to the bracket Withdraw and disconnect the receiver Replacement Ensure on replacement to secure the wiring again with wire straps rev 01 0 01 2002 510 02 67 service manual FPI 5000 I 9 4 2 Flap detector Removal Transmitter LED Remove the base cover as described in paragraph 1 9 Base cover figure 9 7 Refer to figure 9 7 Slacken the nut 7 securing the bracket 8 to the envelope guide plate 2 Carefully withdraw the bracket Take care of the wiring Remove the pan head tapping screw 9 se
49. 1 62 1 29 Envelope support 97 01 00 1 30 Finger knob 74 17 32 1 02 0 02 2002 510 04 61 service manual FPI 5000 I 510 04 62 rev 02 0 02 2002
50. 2 service manual FPI 5000 I Action Call service Info Flap sensor defective During the start of the machine no photo diode current of photocell PH2 15 detected The photodiode is not properly connected or not connected at all This error only may occur after the field replacement of the photocell or after any service activities involving replacing circuit board connections Error 1 58 Message Technical failure Action Call service Info Loc sensor defective During the start of the machine no photo diode current of photocell PH3 1s detected The photodiode is not properly connected or not connected at all This error only may occur after the field replacement of the photocell or after any service activities involving replacing circuit board connections Error 1 59 Message Technical failure Action Call service Info Exit sensor defective During the start of the machine no photo diode current of photocell PH4 is detected The photodiode s not properly connected or not connected at all This error only may occur after the field replacement of the photocell or after any service activities involving replacing circuit board connections Error 1 60 Message Technical failure Action Call service Info Track sensor defective During the paper process the photo diode current of photocell PHI is set at a too high value after the next 25 paper passages This 15 likely caused by not heeding the Clean Sensor warning Clean
51. 2 Figure 1 13 Figure 1 14 Figure 1 15 Figure 1 16 Figure 1 17 Figure 1 18 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Figure 3 9 Figure 3 10 Figure 3 11 Figure 3 12 Figure 3 13 Figure 3 14 Figure 3 15 Figure 3 16 Figure 3 17 Figure 3 18 Figure 3 19 Figure 3 20 Figure 3 21 Figure 3 22 Figure 3 23 Figure 3 24 Figure 3 25 Figure 3 26 510 03 4 Electrical electronic IN 1C block diagram Overview of the IN 1C electrical and electronic circuits including external connections and sensor actuator connections The main board 94 80 01 electronics are divided into five sections items in a specific section are numbered from X00 onwards X 1 5 Main board 94 80 01 electronics 1 power supply Main board 94 80 01 electronics 2 photocells and unit Main board 94 80 01 electronics 3 CPU circuitry Main board 94 80 01 electronics 4 actuator drivers Main board 94 80 01 electronics 5 system connections Component layout of the main board 94 80 01 The FRAM board 95 74 55 electronics Component layout of the FRAM board 95 74 55 The motor relay board 12 16 21 electronics Component layout of the motor relay board 12 16 21 The combined display key circuit board 95 70 72 electronics overview The combined display key circuit board 95 70 72 electronics power supplies and LCD control The combined display key circuit
52. 2 2002 service manual FPI 5000 I Figure 510 04 16 Remarks illustration Description Part code Quantity Remarks code number number FPI 5000 I Inside frame RH 95 73 07 2 Conductive bearing 10 mm 04 24 26 3 Washer 16 x 10 2 x 0 8 mm 04 01 43 4 Spacer 15 x O 10 4 x 3 mm 04 08 58 5 Tension pin 2 5 x 20 05 33 24 6 Sprocket 15T 23 68 86 5 7 Round head screw x 8 45 38 68 3 8 Gear 28T 24 11 40 2 9 Spring clip 9 12 mm 05 24 55 3 10 Tension 2 5 x 16 05 33 22 1 11 Locking plate 43 31 93 1 12 Drive axle including handle assy 83 01 16 1 13 Fixing plate envelope track 95 73 04 1 14 head tapping screw 45 38 55 2 15 Led including holder without lens 04 24 42 1 16 Bracket 43 34 29 1 17 Guide plate 73 66 76 1 18 Washer 12x 4 3 x 1 mm 45 37 43 1 19 Nut M4 45 19 02 2 20 including holder 04 24 53 1 2 Round head screw M3 x 8 45 38 65 5 22 Frame rod 43 29 43 1 23 Conductive strip 04 20 03 2 24 Washer 9 x 04 3 x 0 8 mm 45 37 02 1 25 Inside frame LH 95 73 09 1 26 Air tube plug 24 13 02 2 27 Protective strip 24 12 98 1 28 head screw M6 x 12 05 38 85 4 29 Protective strip 24 08 59 1 30 Handle assy 83 26 66 1 3 Clamping ring 10 mm 05 24 81 1 32 Hex head screw x 8 05 38 80 6 33 Sleeve 04 09 77 2 34 Mounting pin 43 61 75 2 35 Protective strip long 24 12 27 1 36 Frame rod 43 29 45 1 37 Frame transportbridge LH 95 71 09 1 38 Axle 23 28 99 4 39 Mounting brack
53. 3 64 1 24 Spring clip 9 12 mm 05 24 55 2 25 Round head screw x 16 45 43 16 4 26 Washer 0 12x 04 3x 1 mm 45 37 43 6 27 Spacer 8x 4 2 x 8 5 mm 95 73 63 4 28 Mounting plate 95 73 91 1 29 Bracket 95 73 61 1 30 Pulley assy 95 73 77 2 3 Spring clip 10 14 mm 05 24 83 2 32 Springclip8 11 mm 05 24 54 2 33 Washer 14 x 8 2 x 0 8 mm 04 01 41 4 34 Pulley 95 73 62 6 35 Spring clip 4 5 mm 05 24 47 2 36 Conical roller 95 73 68 2 37 Washer 12 x 6 2 x 0 8 mm 04 01 40 2 38 Arm for conical roller 95 73 70 2 39 Torsion spring 1 03 35 35 2 40 Spacer 12 x 9 1 x 2 5 mm 43 01 25 2 4 Spacer 95 x 3 2 x 12 5 mm 95 73 72 2 42 Washer 0 9 x 03 2x 0 8 mm 45 37 46 2 43 Round head screw x 16 45 43 06 2 44 Spacer O8 x 94 3 x 7 5 mm 04 07 78 2 45 Guide plate 95 73 94 1 02 0 02 2002 510 04 55 service manual FPI 5000 I Figure 15 510 04 56 rev 02 0 02 2002 service manual FPI 5000 I Figure 510 04 56 Part code Quantity Remarks number FPI 5000 I illustration code number Remarks Description rev 02 0 02 2002 RP V oo 1 11 13 Side guide incl absorber Absorber Envelope Support incl absorber Round head screw M4 x 10 Washer 9 x 0 4 3 x 0 8 mm Transparent cover Bottom plate Hex head screw M4 x 8 Guide plate Side exit receiving tray Upper plate assy Washer 12 x 4 3 x 1 mm Crinkle washer Nut M4 self locking 97 01 13 24 11 51 95 74 08
54. 510 02 26 rev 01 0 01 2002 service manual FPI 5000 I 3 7 Motor Removal Remove the RH s de cover as described n paragraph 1 3 RH side cover Remove the power supply cover as described in paragraph 1 8 Power supply cover Refer to figure 3 1 Slacken the two hex head screws 10 and release the belt tensioner 29 Remove the main drive belt 33 from the motor pulley 32 figure 3 5 Refer to figure 3 5 Disconnect the motor wiring at the terminal block 1 on the power supply unit 2 Remove the base cover as described in paragraph 1 9 Base cover Refer to figure 3 3 Cut all the wire straps securing the motor wiring on the inside of the machine Remove the four hex head screws 40 with spacers securing the motor 42 Take care of the weight of the motor Withdraw the motor from the machine Take care of the wiring Replacement Ensure on replacement that the motor wiring 1s again secured with wire straps Adjustment See paragraph 10 3 Main drive belt rev 01 0 01 2002 510 02 27 service manual FPI 5000 I 4 Envelope feed 4 1 Hopper Remove the feed platform as described n paragraph 1 13 Feed platform 411 O rings 18 1211 figure 4 1 Removal Refer to figure 4 1 Remove the two round head screws 2 and withdraw the gear cover 7 Remove the spring clip 3 the washers 4 and the bearing 5 from both sides of the feed shaft 15 Shift the feed shaft in the right hand side direction until it clears the L
55. 54 55 52 51 POWER and LCD ctions KEYS 1 2 POWER KEYS figure 1 14 The combined display key circuit board 95 70 72 electronics overview rev 01 0 01 2002 510 03 23 FPI 5000 I service manua 46 352213000 QA 2 Jam Tad 9 pad sad 94g Lad 1 5 AST 33A 440 DATAOZ IND OL st NT p eog IND JT 0c 6L SL il 9 SL vl el 47 LL OL 6 8 2 9 8 v 4 paeoq 7098 140 TUDEJTH ZOOVNL 00 dELOIWHL 00101 TTeus voein OZ vid zur 02141 81164W1 nid ast ezta zz a ASI ozsa Y Y 02 29 N v Mo noL on 7210 OZLYA eco Y Y
56. 8 Conductive bearing 10 mm 04 24 26 9 19 Washer 16 x 010 2 x 0 8 mm 04 01 43 12 20 Nut M5 45 19 03 4 21 Spacer O25x 0 5 5 x 8mm 43 29 31 2 22 Rubber stud 5 x 20 04 12 11 2 23 Motor 220 240V 50Hz 12 09 98 1 Motor 100 115V 60 Hz 12 10 46 1 24 Transportation roller 30 mm 04 18 27 6 25 Cyl pin 02 5 x 16 05 23 46 6 26 Transportation axle 43 26 18 1 27 Transportation axle 43 28 84 1 28 Clutch shaft assy 04 18 37 1 29 Inside frame LH 95 73 09 1 30 Hex head screw x 8 05 38 80 12 3 Airtube plug 24 13 02 2 32 Conductive strip 04 20 03 1 33 Washer 9 x 4 3 x 0 8 mm 45 37 02 1 34 Hinge plate 43 53 70 1 35 Wire strap holder 12 10 52 4 36 Rubber roller 28 mm 73 28 93 1 37 Gear 15T 24 08 57 2 38 Nut M4 45 19 02 3 39 Flap opener 73 53 73 1 40 including holder 04 24 52 1 4 Washer 12 x 4 3 x 1 mm 45 37 43 1 42 Bracket 43 34 12 1 43 head tapping screw 45 38 55 2 44 scraper 43 34 39 1 02 0 02 2002 510 04 13 Figure 510 04 12 Remarks illustration code number 45 46 510 04 14 service manual Description Sensor including holder Bracket FPI 5000 I Part code Quantity Remarks number FPI 5000 I 04 24 53 1 23 46 09 1 02 0 02 2002 service manual FPI 5000 I rev 02 0 02 2002 510 04 15 service manual FPI 5000 I CN 9 1 16 15 14 13 12 2 amp 23 22 21 20 19 18 31 30 29 28 27 26 25 Figure 4 510 04 16 rev 02 0 0
57. 95 05 36 21 95 70 72 45 37 02 95 70 90 95 70 79 97 00 11 97 00 40 45 38 68 04 01 29 04 09 05 NO e A Re DD m rev 02 0 02 2002 service manual FPI 5000 I rev 02 0 02 2002 510 04 41 FPI 5000 I service manua 17 16 15 14 13 12 11 10 37 36 35 34 33 32 40 39 38 45 44 43 42 41 Figure 11 rev 02 0 02 2002 510 04 42 service manual FPI 5000 I Figure 510 04 42 Part code Quantity Remarks number FPI 5000 I illustration Description code number Remarks rev 02 0 02 2002 gt V 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Top cover loc Round head screw M4 x 10 Mounting clamp Solenoid Round head screw M4 x 5 Washer 9 x 0 4 3 x 0 8 mm Pressure spring Draw bar Clamping ring 3 mm Spring clip 6 8 mm Washer 12 x 6 2 x 0 8 mm Transportation roller assy Sealing plug Hinge bracket Bracket Axle short Hinge axle long Frame upper plate loc Nut M4 Brake plate assy Washer 12 x 4 3 x 1 mm Cover loc Set screw M3 x 4 Tension pin 2 5 x 16 Gear 18T Conductive bearing 10 mm Washer 16 x 10 2 x 0 8 mm Bushing 15 x 10 x 5 5 mm Lock washer 5 32 Countersunk head screw M4 x 10 mm Cover Round head screw M4 x 16 Bushing 16 x 8x 8 mm Protective plate Pressure spring mm Nyl
58. FPi 5000 Inserting System FRANCOTYP POSTALIA 0 lt a t ho U FPI 5000 FPI 5000 C SERVICE MANUAL service manual FPI 5000 I FPI 5000 Inserter rev 01 0 01 2002 service manual Contents Section General Process description Mechanical description Electrical description Parts list Fault finding FPI 5000 I Page 510 00 1 510 01 1 510 02 1 510 03 1 510 04 1 510 05 1 rev 01 0 01 2002 service manual FPI 5000 I General rev 01 0 01 2002 510 00 1 service manual FPI 5000 I 510 00 2 rev 01 0 01 2002 rev 01 0 01 2002 2 1 22 3 1 3 2 service manual Contents Section Function Specifications Machine specifications Envelope and paper insert specifications Preparing the machine for use Unpacking Unpacking instruction Preventive maintenance FPI 5000 I Page 510 00 3 service manual FPI 5000 I 510 00 4 rev 01 0 01 2002 service manual FPI 5000 I Used symbols In th s manual the following symbols are used Warning this symbol indicates a wrong action which can cause a hazard to health or damage the machine Warning this symbol indicates a hazard to life because of high voltage rev 01 0 01 2002 510 00 5 service manual FPI 5000 I 1 Function The FPI 5000 I inserts documents from the upstream feeding device FPI 5000 C into envelopes and the seals and stacks the envelopes
59. H inside frame 6 Take care of the spacer 9 and the gear 10 Tilt the left hand side of the feed shaft in the rear side direction and when possible withdraw it in the left hand side direction Push the O rings 13 from the two joggers 11 and 14 and remove them from the feed shaft 510 02 28 rev 01 0 01 2002 service manual FPI 5000 I 4 1 2 Rollers Separation roller Note Before removing the separation roller first check the adjustment procedure as described in paragraph 10 7 Removal Refer to figure 4 1 Turn thumbweel 1 counterclockwise and set the separation gap to the maximum Slacken the two set screws of the feed roller 12 Slide the feed roller in the left hand side direction against the jogger 11 Remove the two round head screws 8 and withdraw the rod 16 with the separation roller 17 Slacken the set screws of the separation roller and slide it off the rod Feed roller Removal Remove the feed shaft as described in the previous paragraph Refer to figure 4 1 Push the O ring 13 from the jogger 14 and remove it from the feed shaft 15 Slacken the set screw of the jogger Slide the jogger off the feed shaft Slacken the two set screws of the feed roller 12 Slide the feed roller off the feed shaft Replacement On replacement position the feed roller in the middle of the feed shaft and the removed jogger at an equal distance from the feed roller as the other jogger Ensure that the set screws of the feed roller
60. Message Envelope stoppage Action Remove envelope Info Seal switch not covered The ejected document doesn t reach the sealing flag switch FS in time Error 1 27 Message Document stoppage Action Remove documents Info Document too late After an upstream FPI 5000 C document call no document reaches the document photocell PH3 Error 1 28 Message Document stoppage Action Remove documents Info Document too thick The document is thicker than the reference thickness Remove the envelope and the document from the insert table This error message is issued if the document is more than 40 micrometer thicker than the reference thickness A 45 g per cm sheet of paper has a thickness of about 50 micrometer This error message only is issued if the DFC function is activated and if the reference thickness is known See also error 14 Error 1 29 Message Document stoppage Action Remove documents Info Insert area blocked During the start of machine processing a document is present on the insert table Remove this document Error 1 30 Message Empty envelope hopper Action Load envelopes Info none Error 1 31 Message Technical failure Action Call service Info Fuse 3 blown Fuse 3 defective No external 24 V 24V _1 Replace fuse after inspecting the electronics for possible causes Error 1 32 Message Technical failure Action Call service Info Fuse 4 blown Fuse 4 defective No ex
61. N 510 04 7 FPI 5000 I service manua 9 10 11 12 13 14 15 64 63 62 38 37 36 35 34 33 16 17 18 19 20 21 22 14 73 72 48 47 46 45 Figure 2 rev 02 0 02 2002 510 04 8 service manual FPI 5000 I Figure 510 04 8 Part code Quantity Remarks number FPI 5000 I illustration code number Remarks Description rev 02 0 02 2002 RP V oO SO DN m 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Spring clip4 5 mm Fibre washer 8 x 4 2 x 0 5 mm Washer 12 x 4 3 x 1 mm Bearing bracket assy Torsion spring Round head screw MA x 8 Hinge bracket Round head screw MA x 10 Flatcable DFC Earth wire Lock washer 5 32 Round head screw M4 x 16 Fixing bracket Inside frame RH Frame document detector Damper Bracket for finger center Nut M4 self locking Hinge axle Spring clip 7 9 mm Washer 16 x 10 2 x 0 8 mm Nylon bearing 8 mm Cupped spring washer Bracket for finger Round head screw 4 x 20 Fixing rod Pressure spring 0 85 mm Conductive bearing 10 mm Clamping ring 12 mm Pressure spring 0 7 mm Round head screw MA x 8 Drive axle Connecting plate RH Front plate Round head screw M3 x 8 Fibre washer 17 x 10 2 x 0 5 mm Feed table Connecting plate LH Mounting clamp Hex head screw M4 x 8 Nut M5 Strain relief Spacer 25 x
62. _ R218 R217 216 215 R214 R213 R212 R211 5214 5213 aaf 10141 00 91 5000 I CE IC A8Z 019 ZEN Q N lt 4 z 79 gt m r A lon 0011 60141 S211A 5211 figure 1 17 Component layout of the combined display key circuit board 95 70 72 510 03 26 rev 01 0 01 2002 service manual FPI 5000 I 5v N 5K UGN3503 N 1 2 5 10K J1 6 43 1 4 A4 R5 1 4K8 2 15 2 10N 1 150kl2 CONG GNO GND GNO GNO GNO figure 1 18 The local electronics of the DFC unit 83 29 91 rev 01 0 01 2002 510 03 27 service manual FPI 5000 I 2 Settings The FPI 5000 I doesn t need any electrical or electronic settings by service personnel However the correct operation of the DFC unit may be verified This s the factory setting which must be used after replacing the DFC unit DFC verification Correct operation of the DFC unit can be verified as follows Switch the FPI 5000 I off Slightly slacken the two screws of the DFC mounting bracket These are accessible after lifting the loc Place a feeler gauge with a thickness of 4 mm between the feelers ball bearings Push the mounting bracket down and tighten the screws Remove the feeler gauge Switch the FPI 5000 I on During sta
63. age is applied during the startup of the machine The relevant DAC setting is not stored in FRAM The mechanical adjustment of DFC see chapter 3 involves a preset at Imm of a total range of 5 mm in order to use the linear part of the Hall sensor only Motor The main motor MI is switched on and off by the motor relay REI See the motor relay board electronics of figure 1 12 for the relay circuit details The CPU controls this relay via buffers The motor provides mechanical power to the FPI 5000 I the FPI 5000 C base unit and its attached feeder units For a sufficient starting torque capacitor C2 1s temporarily switched parallel to motor capacitor After reaching a certain rpm rate monitored by pulse disc PD1 the start relay RE2 is switched off If the motor doesn t reach its nominal rpm rate within one second it is switched off and an error message is issued The motor is thermally protected against overheating due to mechanical blocking A chain of micro switches is included in series with the motor relay circuit This chain consists of the FPI 5000 I micro switches top cover directly connected with J2 of the motor relay board and MS2 side cover connected with J540 on the main board and the micro switches on the FPI 5000 C base unit The latter micro switches are connected in series between pins B5 and B2 of the FPI 5000 C system connector This means that an opened cover on the FPI 5000 I or on the FPI 5000 C base unit
64. al play on the axle Gear 15T item 23 Removal Refer to figure 6 3 Remove the two round head screws 24 from both sides of the loc frame Refer to figure 6 5 Carefully withdraw the cradle together with the draw bar 12 and the plunger 11 Take care of the two washers 277 and the spacer 19 on both sides of the axle 21 and of the pressure spring 10 and the two washers 9 on the plunger Slide the axle out of the cradle and withdraw the gear 23 Take care of the bearings 20 26 and the spacers 22 and 24 13 14 15 9 figure 6 5 510 02 52 rev 01 0 01 2002 service manual FPI 5000 I Gear 15T item 7 Removal Remove the gear 207 item 8 as described in paragraph 6 3 2 Gears gear 20T item 8 Refer to figure 6 5 Remove the pressure spring 14 Slacken the set screw of the roller 16 and slide it off the axle 13 Remove the washer 17 the spacer 18 and the bear ng 15 from the axle Withdraw the axle in the left hand side direction and slide the spacer 8 and the gear 7 off it Take care of the spacer 6 the washer 5 the bearing 4 the spacer 3 and the washer 2 6 3 3 Ejection solenoid Removal figure 6 6 Refer to figure 6 6 Disconnect the wiring of the solenoid coil 5 Remove the two round head screws 6 with the washers 7 securing the solenoid coil to the loc frame Slide the solenoid coil from the plunger 2 attached to the draw bar 1 and withdraw it Take care of the two washers 4 and the pressure spring 3 o
65. ant to give in this context some additional information on the various actuators The vertical track clutch VCL drives the vertical transport system and provides primary drive to the two four or six feeder clutches This clutch and the related gears pulleys and timing belts is present at the RH side of the machine It is mounted on the input axle to which the mechanical drive from the FPI 5000 I is transferred The primary drive for the folding system clutch VCL2 is derived from the FPI 5000 I input axle as well This clutch drives the Eight in One subsystem of the three lower and three upper green rollers and provides primary drive to the fold table 1 clutch VCL3 the fold table 2 clutch VCLA In addition to this the VCL2 driven mechanical subsystem also provides the primary drive to the forward shunt clutch VCL5 and the reverse shunt clutch VCLO The fold table 1 clutch VCL3 drives various items for fold table 1 via a cam disk The cam disc position is monitored by the slotted photocell VSPH2 The fold table 2 clutch VCLA drives various items for fold table 2 via a cam disk The cam disc position is monitored by the slotted photocell VSPH3 The forward shunt clutch VCL5 has a number of functions 1 It activates the transport of a completed set of documents into the Eight in One subsystem 2 It transports sets affected by double feed errors from the collator area to the Divert amp Go that is directly accessible by the operator and from whi
66. apacitor 20 mF 110 V 12 12 81 1 16 Capacitor 6 mF 220 V 12 12 80 1 Capacitor 20 mF 110 V 12 12 81 1 17 Print board holder 04 16 57 4 18 Unit motor transformer board 12 16 21 1 19 Round head screw x 16 45 38 67 2 20 Washer 6x 03 2 0 5 mm 45 37 30 2 21 Spacer 6x 3 2x3mm 04 11 12 2 22 Insulating plate 04 11 95 2 23 Microswitch 12 12 22 1 24 Countersunk head tapping screw 45 38 59 2 25 Cover power unit 95 70 55 1 26 Rubber stop 04 12 20 1 27 Round head tapping screw 45 38 58 2 28 Fuse 3 A slow blow 220 V 12 11 12 1 Fuse5 A slow blow 110 V 12 15 49 1 29 Power inlet 82 15 06 1 30 Nut M4 45 19 02 1 3 Transformer support 23 34 48 1 32 Fixing plate 95 73 06 1 33 Print board holder 04 12 99 4 34 Spacer 10x 5 3 x 10 mm 04 09 51 2 35 Spacer 04 10 75 3 36 Grommet 12 08 51 1 37 Mounting clamp 12 14 89 2 38 Washer 12x 4 3 x 1 mm 45 37 43 1 39 Round head screw MA x 10 05 38 69 1 40 Unit F RAM 2K 95 74 55 1 41 Flatcable RAM 04 23 41 1 02 0 02 2002 510 04 39 Figure 510 04 38 Remarks 510 04 40 illustration code number 42 43 44 45 46 47 48 49 50 51 92 service manual Description Fuse 15 A Nut M4 self locking IL CD Keyboard Washer 9 x 4 3 x 0 8 mm Magnetic clip Buffer Knob red Knob green Round head screw M4 x 8 Fibre washer 17 x 10 2 x 0 5 mm Sealing plug Part code FPI 5000 I Ouantity Remarks number FPI 5000 I 12 12
67. ars both sides of the pulse disc and that the detector sees the outer ends of the slots in the pulse disc Secure the wiring again to the bracket with a wire strap rev 01 0 01 2002 510 02 65 service manual FPI 5000 I 9 3 Document thickness detector Removal Remove the electronics cover as described in paragraph 1 5 Electronics cover Open the loc as described in paragraph 1 1 Loc figure 9 5 Refer to figure 9 5 Remove the lower round head screw 1 with washer Remove the upper round head screw 2 with washer Withdraw the bracket 3 with the detector in the rear side direction through the gap in the frame plate 5 Take care of the wiring Remove the round head screw 4 securing wiring of the detector Disconnect and withdraw the bracket with the detector from the insert area Replacement To ensure a correct operation of the thickness detector follow on replacement the procedure as described below Do not tighten the two screws of the thickness detector mounting bracket yet if they have been tightened already loosen the two screws e Place a feeler gauge with a thickness of 4 mm between the feelers ball bearings e Push mounting bracket down and tighten the two screws Remove the feeler gauge Adjustment The document thickness detector does not have any further adjustments Refer to paragraph 3 2 2 of the electrical description for verification of the thickness detector 510 02 66 rev 0
68. ation Error 3 01 Message Technical failure Action Call service Info Defective memory No job settings can be read from the FRAM memory chip IC102 on the FPI 5000 C base unit board 97 50 10 These FRAM settings are lost but the job settings are also available in the FPI 5000 I documents must be removed from the machine Press the Reset key on the FPI 5000 I The paper photocells will be readjusted Error 3 02 Message Technical failure Action Call service Info Defective memory No statistical data counters etc can be read from the FRAM memory chip IC102 on the FPI 5000 C base unit board 97 50 10 The FRAM settings are lost All documents must be removed from the machine Press the Reset key on the FPI 5000 I The paper photocells will be readjusted Error 3 03 Message Technical failure Action Call service Info Option key defective rev 01 0 01 2002 510 03 67 service manual FPI 5000 I If a dongle is present on the FPI 5000 C base unit board 97 50 10 and if the data contained in this dongle appears to be corrupted this message 15 issued After pressing the Reset key on the FPI 5000 I the default settings are being used instead Error 3 10 Message Document stoppage Action Remove documents Info Stoppage at vert track This error message 1s generated if after a document call to a feeder it takes too long for the document to reach the vertical transport photocell VPHI or if this photoce
69. ation axle narrowing part of both rollers pointing outwards Third set of transportation rollers 36 mm Removal Remove the long chain as described in paragraph 3 1 2 Long chain Refer to figure 5 2 Push the two transportation rollers 3 in the right hand side direction from the cyl pins below Remove the two cyl pins from the transportation axle 2 Remove the spring clips 5 from both sides of the transportation axle Withdraw the transportation axle in the right hand side direction out of the machine and slide the two transportation rollers off it Take care of the washers 1 and the bearings 20 on both sides Replacement Ensure on replacement that the two transportation rollers are refitted correctly on the transportation axle narrowing part of both rollers pointing in the left hand side direction rev 01 0 01 2002 510 02 43 service manual FPI 5000 I 5 3 Finger solenoid Open the loc as described in paragraph 1 1 Loc Remove the RH side cover as described in paragraph 1 3 RH side cover Removal figure 5 3 Refer figure 5 3 Disconnect the wiring of the solenoid coil 3 Remove the two hex head screws 1 with washers securing the solenoid coil to the stud 2 Slide the solenoid coil from the plunger 4 and withdraw it Adjustment See paragraph 10 5 Solenoids 510 02 44 rev 01 0 01 2002 service manual FPI 5000 I 6 Loc 6 1 Covers and plates Loc cover Removal Refer to figure 6 1 Remove
70. board 95 70 72 electronics keys Component layout of the combined display key circuit board 95 70 72 The local electronics of the unit 83 29 91 Flowchart of the IN 1C FV 2A service software The two part MAIN MENU The menu JOB ACCESS The main SERVICE MENU The INSERTER service menu The menu SENSORS The screen for the IN PHOTO CONDITION The menu IN DIGITAL INPUTS The DFC output voltage menu The menu ACTUATORS The menu DISPLAY The menu KEYBOARD The menu Reset Data The menu VERTICAL SYSTEM The FOLDER OFFSET menu The FV CONFIG SETTINGS menu The two menu screens for the FV SERVICE TESTS The two screens for the FV PHOTO CONDITION The two screens for the FV DIGITAL INPUTS The two menu screens for the FV ACTUATOR TESTS The submenu for the FV ACTUATOR TESTS The screen for the FV DFC TEST The menu Define collator stops The system wide SERVICE MENU The SOFTWARE VERSION screen The RUN IN TEST screen FPI 5000 I 12 13 14 15 16 17 18 19 20 21 22 22 23 23 24 25 26 21 30 31 31 31 32 32 33 34 34 35 35 36 37 38 38 39 40 41 42 43 44 44 45 45 46 46 rev 01 0 01 2002 service manual Index of Illustrations Figure 3 27 Figure 3 28 Figure 3 29 Figure 3 30 Figure 3 31 Figure 3 32 Figure 3 33 Figure 3 34 Figure 3 35 Figure 3 36 The LOCALISATION menu The menu JOB SETTINGS T
71. both sensors of the photocell Error 1 61 Message Technical failure Action Call service Info Flap sensor defective During the paper process the photo diode current of photocell PH2 is set at a too high value after the next 25 paper passages This is likely caused by not heeding the Clean Sensor warning Clean both sensors of the photocell Error 1 62 Message Technical failure Action Call service Info Loc sensor defective During the paper process the photo diode current of photocell PH3 is set at a too high value after the next 25 paper passages This is likely caused by not heeding the Clean Sensor warning Clean both sensors of the photocell Error 1 63 Message Technical failure rev 01 0 01 2002 510 03 61 service manual FPI 5000 I Action Call service Info Exit sensor defective During the paper process the photo diode current of photocell PHA is set at a too high value after the next 25 paper passages This is likely caused by not heeding the Clean Sensor warning Clean both sensors of the photocell Error 1 64 Message Track sensor dusty Action Clean sensor Info none Dust warning for photocell PHI There 15 still a dust margin available but it is advised to clean both sensors of PHI and to readjust this photocell Error 1 65 Message Flap sensor dusty Action Clean sensor Info none Dust warning for photocell PH2 There is still a dust margin available but it is advised t
72. by pressing the quick stop key 1 e turning the motor off Error 1 21 Message Thickness not measured Action Remove documents Info Wrong measurement area The DFC didn t measure the document The DFC function must be activated This can happen with narrow paper Remove the envelope and the document from the insert table Error 1 22 Message Envelope stoppage Action Remove envelope Info Wrong envelope size The envelope on the insert table is too small in height The minimum envelope height for proper processing by the sealing rollers is about 75 mm Error 1 23 Message Technical failure Action Remove envelope Info Seal switch active At the moment that an envelope has to be ejected from the insert position the sealing flag switch is covered FSI isn t properly mounted or connected or some other mechanical error occurs Error 1 24 Message Document stoppage Action Remove envelope Info Seal switch active The sealing flag switch FS1 remains covered too long This error message is issued during a running motor and with a paper length exceeding 305 mm Error 1 25 Message Envelope stoppage Action Remove envelope 510 03 56 rev 01 0 01 2002 service manual FPI 5000 I Info Seal switch not covered The ejected document doesn t trigger the flag switch FS1 long enough This may happen in the fold only mode with thin paper or the flag switch 1sn t properly mounted Error 1 26
73. can continue by pressing the Reset key Error 4 5 6 7 8 9 61 Message Technical failure rev 01 0 01 2002 510 03 75 service manual FPI 5000 I Action Call service Info DFC defective During the start of the system the offset voltage for each unit is adjusted This error is issued if this adjustment fails This DFC unit is switched off The feeder unit communicates to the inserter that the feeder has no DFC unit On the FPI 5000 I the DFC function can not be selected for this feeder The operator can continue by pressing the Reset key Error 4 5 6 7 8 9 62 Message Technical failure Action Call service Info DFC defective During the start of the system the presence of each DFC unit is checked for If a DFC unit is not present this function is internally switched off in the relevant feeder If the DFC unit has gone defective the DFC unit is considered absent as well If a job 1s selected which requires the absent DFC function and the feeder 1s order to switch on its DFC function this error 1s issued The feeder unit communicates to the inserter that the feeder has no DFC unit On the FPI 5000 I the DFC function can not be selected for this feeder The operator can continue by pressing the Reset key Error 4 5 6 7 8 9 70 Message Technical failure Action Call service Info Power failure The 12 V power supply voltage in feeder unit x x 1 3 is too low Error 4 5
74. certain conditions this document can be prevented from being folded This can be implemented with the menu BRE offset BRE means Business Reply Envelope of figure 3 34 For each of the jobs 1 through 9 and Fill amp Start an offset can be switched on or off In the case of offset on the last document that had been added to the set prior to further processing will be shifted from the rest of the set offsetting 1 e this document will be held back during a certain distance This means that the trailing edge of this upper document leaves the collator as last This document will not be folded During the insertion into the envelope the documents of the set will be realigned The conditions are feeder that supplies this upper document BRE is set to one document per set no multi feeding document directly beneath this document must be at least 60 mm longer than the BRE The upper document must be longer than the set address fold e The folding mode is either single fold or letter fold so no Z fold The upper document must be shorter than the envelope height rev 01 0 01 2002 510 03 49 service manual FPI 5000 I SERVICE COUHTERS Since last visit Since 3884 installation Hext visit after 100000 Save and exit Note It is possible to use the BRE offset for a BRE and an enclosure card in 1 set The extra condition is that this enclosure is equal to or smaller than the set address fold and
75. ch this set can be taken away 3 If successive documents from the same feeder are processed multifeeding the forward shunt clutch VCLS activates the transport of a partially completed set from the collator area to the shunt area prior to transporting it back to the collator area together with the next vertically transported multifed document of this set If successive documents from the same feeder are processed multifeeding the reverse shunt clutch VCL6 activates a movement in which a partially completed set is transported from the shunt area back to the collator area together with the next vertically transported multifed document of this set The collator motor VMI drives the collator transport mechanism Its movement is monitored by a pulse disc and the slotted photocell VSPH4 In one direction documents are fed from the vertical track and or shunt area into the collator area In the other direction a completed set is transported to the Eight in One subsystem or a partially completed set 510 03 42 rev 01 0 01 2002 service manual FPI 5000 I ACTUATOR TESTS of a set to which multifed documents are added is transported to the shunt area A third possibility refers to a set affected by double feed errors The latter two possibilities require the presence of the divert unit The divert unit motor VM2 drives the divert unit Its movement is monitored by the slotted photocell VSPHS This unit drives the divert flap i e a choice be
76. connections figure 1 8 on page 510 03 19 e FRAM board 95 74 55 figure 1 10 on page 510 03 21 e Motor relay board 12 16 21 figure 1 12 on page 510 03 22 e Combined display key circuit board 95 70 72 electronics figure 1 14 figure 1 15 figure 1 16 on pages 510 03 23 510 03 24 and 510 03 25 Local DFC electronics figure 1 18 on page 510 03 27 Component layouts of the five boards figure 1 9 on page 510 03 20 figure 1 11 on page 510 03 22 figure 1 13 on page 510 03 23 and figure 1 17 on page 510 03 26 Main board block diagram In the block diagram of figure 1 1 the input devices keyboard sensors and output devices of the main board display actuators are logically grouped The upstream PC communication of the 5000 I is dedicated to the FPI 5000 C base unit The latter communicates by PC with one or more feeder units Main board CPU The program code for process control user interface and SCS message handling is stored in the non volatile CMOS EPROM memory chip U330 with 128 kilobytes of memory This program code Eprom 98 02 11 is executed by the micro controller 0300 the 80C552 This CPU has six 8 bit ports Port P5 can be configured as a 10 bit A D converter with 8 multiplexed inputs Port P2 forms the high address byte port PO 15 the ALE multiplexed 8 bit data bus annex low address byte of the address bus In addition to 8 kilobytes of volatile RAM in U340 various chips around the CPU perform all ki
77. ctivation of RPM1 and solenoids Sol through S05 Refer to figure 1 7 for more details The exit solenoid S05 and the fingers solenoid Sol are driven by the pulse modulated outputs PWMO and PWMI of the 80C552 CPU This offers the possibility of reducing heat dissipation in these solenoids FRAM board 95 74 55 The FPI 5000 I uses volatile memory This is used for storing both operational data and machine configuration data pertaining to either FPI 5000 I specific FPI 5000 C specific all system wide information The FRAM type as used on the FRAM board 95 74 55 see figure 1 10 has a data storage capacity of 2048 bytes in stead of the 512 bytes used in other systems This reflects the fact that FPI 5000 C related data has to be partially accommodated except for local photocell and DFC settings for as well On the FRAM board a dongle can be mounted for a future protection of certain customized options for instance reading options 510 03 10 rev 01 0 01 2002 service manual FPI 5000 I Software The FPI 5000 I software in the Eprom 98 02 11 has anumber of tasks a process control b user interface c domestic tasks via the simulated bus d SCS communication with the FPI 5000 and its attached feeder units including messaging rev 01 0 01 2002 510 03 11 service manual FPI 5000 I MS Pulse A i DF FS MS2 s PH3 PHA SCS Upstream SA IM500 Main board gt Power supply A Mechanical drive Main mot
78. curing the transmitter 1 to the bracket Withdraw and disconnect the transmitter Receiver Sensor Remove the insert table as described in paragraph 1 12 Insert table Refer to figure 9 7 Pull the air hose from the receiver 4 Slacken the hex head screw 3 and withdraw the bracket 5 Take care of the wiring Cut the wire straps securing the wiring to the bracket Remove the pan head tapping screw 6 securing the receiver to the bracket Withdraw and disconnect the receiver Replacement Ensure on replacement to secure the wiring again with wire straps 510 02 68 rev 01 0 01 2002 service manual FPI 5000 I 9 4 3 Exit detector Open the loc as described in paragraph 1 1 Loc Remove the RH side cover as described in 1 3 RH side cover Open the LH hinged side cover as described in paragraph 1 4 LH hinged side cover Removal figure 9 8 Refer to figure 9 8 Remove the round head screws 2 securing the frame rod 3 to both inside frames Slacken the round head screws 1 securing the frame rod 9 to both inside frames Carefully tilt the cover plate 8 in the rear side direction Take care of the wiring Transmitter LED Refer to figure 9 8 Remove the countersunk tapping screw 5 securing the transmitter 6 to the cover plate Withdraw and disconnect the transmitter Receiver Sensor Refer to figure 9 8 Remove the countersunk tapping screw 4 securing the receiver 7 to the cover plate Withdraw and disconnect
79. d in each reading feeder Error 4 5 6 7 8 9 50 Message Feeder sensor dusty Action Clean sensor Info Dusty sensor The relevant photocell is dusty to such an extend that the full 100 of the photodiode current has been reached Readjust the photocell after cleaning with no paper present Error 4 5 6 7 8 9 51 Message Feeder sensor dusty Action Clean sensor Info Dusty sensor Sensor needs readjustment after removed dust causes a too high LED current setting of the relevant photodiode Error 4 5 6 7 8 9 52 Message Technical failure Action Call service Info Feeder sensor defective The photocell transmitter receiver combination of feeder x x 6 is defective Check the wiring of both photocell parts Error 4 5 6 7 8 9 53 Message Technical failure Action Call service Info Feeder sensor defective The photocell transmitter LED of feeder x x 1 6 1s defective Check the wiring Error 4 5 6 7 8 9 60 Message Technical failure Action Call service Info DFC defective If the adjacent photocell sees paper but if the relevant DFC unit does not reflect its thickness in its output voltage this might indicate a mechanical failure of the DFC unit This DFC unit is switched off The feeder unit communicates to the inserter that the feeder has no DFC unit On the FPI 5000 I the DFC function can not be selected for this feeder The operator
80. d trailing edge of the envelope The envelope then passes the flap rollers The combined action of the flap scraper and the lower linear speed of the flap rollers compared with the speed of the third envelope transport rollers results in some buckling and the opening of the envelope The flap 1s the trailing part of the envelope passing the flap rollers and the flap detector PH2 Pulse measurements by pulse disc PD1 during the presence of the envelope under and PH2 provide information on a the length of the not yet opened envelope b the opened envelope and c the time at which the envelope transport is suddenly stopped with the envelope on the insert table The sudden stop is the result of disengaging by RPMI and the friction brake The envelope flap now is fixed between the flap holder rollers 2 2 Document input and insert Once the envelope is on the insert table the fingers solenoid Sol is activated Five fingers are moved forward into the envelope This is necessary to insert the document set in the envelope The FPI 5000 I now orders the FPI 5000 C feed the document or document set to be inserted This document set passes a three pairs of document rollers b the DFC unit for a thickness check the insert rollers d document detector PH3 and e the fingers before entering the envelope 2 3 Envelope ejecting sealing and exiting rev 01 0 01 2002 510 01 7 service manual FPI 5000 I The inse
81. e Frame rod Connecting plate loc Tension spring 0 5 mm Countersunk head screw M4 x 10 Round head screw M4 x 16 Round head screw M4 x 6 Nut M4 self locking Crinkle washer Washer 12 x 5 2 x 0 7 mm Axle Hex head screw M4 x 8 Locking spring Brush holder Brush Countersunk head screw M4 x 10 Lifting bracket Retaining spring Grommet Conductive bearing 10 mm Pressure spring Bracket Sleeve Washer 16 x 10 2 x 0 8 mm Spring clip 9 12 mm Leaf spring Transportation roller 38 mm Set screw M4 x 4 Spring lever Nut M4 Washer 12 x 4 3 x 1 mm Tension spring Spacer 15 x 10 4 x 10 mm Transportation roller 36 mm Pressure spring 0 7 mm 15 37 53 24 09 36 05 33 22 43 34 21 04 24 52 95 74 53 45 38 53 05 38 68 12 10 52 43 25 84 43 25 74 95 72 60 03 11 81 05 38 75 05 38 71 05 38 66 05 36 21 05 24 84 43 05 35 23 29 10 05 38 80 03 23 74 46 04 60 72 00 05 45 38 75 94 80 08 03 11 87 12 04 74 04 24 26 03 11 14 33 34 59 04 09 77 04 01 43 05 24 55 03 34 77 76 04 67 08 28 01 23 28 74 45 19 02 45 37 43 45 64 04 04 08 30 76 04 66 03 11 11 Pu 31 KR BE M We On e AI VV NY Re U eS DD BRR 510 04 51 Figure 510 04 50 Remarks 510 04 52 illustration code number 45 46 47 48 49 50 51 22 53 service manual Description Axle Spacer 15 x
82. e cycle of the machine operating in the automatic mode The operator can choose the execution of a single cycle or a two stage cycle as well rev 01 0 01 2002 510 01 5 service manual FPI 5000 I 510 01 6 rev 01 0 01 2002 service manual FPI 5000 I 2 Some details The inserting and sealing process controls a number of rotating or otherwise moving items A motor provides the overall mechanical drive The machine controls the process by means of output devices called actuators This control is based on information supplied by input devices called sensors The control action itself 15 a program software This program also talks with the operator via a keyboard and a display The drawing on foldout page 510 01 6 shows a LH side projected overview of all the moving items sensors and actuators of the FPI 5000 I It is a summary of more detailed information discussed in the mechanical description document 510 02 2 1 Envelope transport the rollers for this process stage are engaged to the main drive by clutch RPMI During the document and insert stage these rollers are disengaged In the final ejecting sealing and exiting stage these rollers are engaged once again to release the envelope and to feed a new envelope First of all by the action of the feed and separation rollers an envelope is separated from the stack in the hopper and transported via three pairs of transport rollers The envelope detector PHI detects the leading an
83. ectrical rev 01 0 01 2002 510 03 1 service manual FPI 5000 I 510 03 2 rev 01 0 01 2002 rev 01 0 01 2002 3 1 2 252 3 2 2 3 2 3 3 2 4 kaa 3 2 6 3 3 3 3 1 3 3 2 3 3 3 3 3 4 3 4 3 4 1 3 4 2 3 4 3 3 4 4 3 4 5 5 1 3 2 5 3 5 3 1 22 2 5 3 3 5 4 service manual FPI 5000 I Contents Section Preliminary note Electrical and electronic operation Settings Service software General The INSERTER service software The menu SENSORS The menu DFC The menu ACTUATORS The menu DISPLAY The menu KEYBOARD The menu Reset Data The VERTICAL SYSTEM menu The FOLDER OFFSET menu The FV CONFIG SETTINGS menu The FV SERVICE TESTS menu The Set default collator stop menu The system wide SERVICE MENU SOFTWARE VERSIONS RUN IN TEST LOCALISATION JOB SETTINGS The SERVICE COUNTERS menu Test points Error diagnosis and error codes IN 1C error codes and warnings Other IN 1C diagnostic information FV 2A feeder unit related error codes Folder subsystem Vertical transport subsystem Feeder subsystem Other FV 2A feeder unit related diagnostic information Page 28 29 20 32 32 34 35 35 36 36 37 38 39 40 45 45 46 46 47 47 50 52 53 53 65 65 65 67 73 71 510 03 3 service manual Index of Illustrations Figure 1 1 Figure 1 2 Figure 1 3 Figure 1 4 Figure 1 5 Figure 1 6 Figure 1 7 Figure 1 8 Figure 1 9 Figure 1 10 Figure 1 11 Figure 1 1
84. eding of a document one or more FPI 5000 I covers are opened Error 1 103 Message Envelope stoppage Action Remove envelope Info Cover open During the ejecting of the filled envelope one or more FPI 5000 I covers are opened Error 1 104 Message Envelope stoppage Action Remove envelope Info Cover open During the exiting of the filled envelope one or more FPI 5000 I covers are opened Error 1 105 Message Technical failure Action Call service Info Communication failure There is IC communication between 5000 I and the 5000 C so one or more errors 1 80 1 89 do not apply However after establishing the SCS NEXT signal the SCS READY signal doesn t go to the low level Error 1 106 Message Illegal configuration Action Wrong upstream device Info Devices do not match The SCS upstream identification software of the FPI 5000 I detected an unknown SCS upstream configuration Note The FPI 5000 I is dedicated to the vertical system and cannot be used in any short or long horizontal configuration 510 03 64 rev 01 0 01 2002 service manual FPI 5000 I Warning unnumbered Message Cover open Action Close cover Info none An FPI 5000 I cover is opened during the pause mode of the machine Opening a cover during processing paper leads to one of the errors 1 101 1 104 5 2 Other 5000 diagnostic information Two LED s on 5000 I main board have a d
85. er present In this way a feedback system ensures that within a certain valid range of both the DAC settings and the no paper output voltages the presence absence of paper dust on the various photocell lenses is compensated by a higher lower current 1 e infrared brightness through the relevant photodiode Readjustments either to a higher or lower DAC value take place after each 25 paper passages In this way the quality of the paper no paper decision making is fairly guaranteed Various error messages may be issued if the adjustments result in either invalid DAC settings or an invalid no paper output voltage The DAC settings are stored in non volatile FRAM Pulse disc flag switch and micro switches The pulse disc 1 is mounted on the driven sealing track roller The rotating disc has a number of cogs which periodically interrupt the infrared beam between a photodiode and a phototransistor This results in a stream of pulses which eventually are fed to the CPU The pulses are used for various process timings There is a linear relationship between the mechanical displacement and the number of pulses The pulse count is also used for verifying the proper rpm rating 1 e the proper starting and running of the main motor M1 The optical flag switch FS1 in the sealing track is based on a pawl which when triggered interrupts the infrared beam between a photodiode and a phototransistor It starts a pulse count for determining the time at which the
86. et 43 34 41 1 40 Lever complete 73 22 54 1 41 Lifting plate 26 04 54 1 42 Tension spring 03 11 54 1 43 Transportation axle 43 26 16 1 44 Guide axle 95 71 11 2 45 Transportation roller 30 mm 04 18 27 4 rev 02 0 02 2002 510 04 17 Figure 510 04 16 Remarks 510 04 18 illustration code number 46 47 48 49 50 51 22 53 54 29 56 57 service manual Description Cyl pin 2 5 x 16 Insert table Countersunk head screw M3 x 10 Spring clip 10 14 mm Pulley axle assy Frame rod Pressure spring 1 mm Frame transportbridge RH Pressure spring 0 85 mm Set screw MA x 8 Transportation roller 30 mm Frame rod Part code FPI 5000 I Quantity Remarks number FPI 5000 I 05 23 46 95 73 11 05 38 74 05 24 83 04 23 19 43 29 44 03 11 88 95 71 10 43 11 12 08 28 06 46 04 56 43 42 91 O Be 00 me rev 02 0 02 2002 service manual FPI 5000 I rev 02 0 02 2002 510 04 19 service manual FPI 5000 I 19 20 21 22 23 24 16 17 18 12 13 14 15 34 33 32 1 2 3 4 5 6 7 8 Figure 5 510 04 20 rev 02 0 02 2002 service manual FPI 5000 I Figure 510 04 20 Remarks illustration Description Part code Quantity Remarks code number number FPI 5000 I 1 Inside frame 95 73 07 1 2 Round head screw MA x 16 05 38 71 12 3 Countersunk head screw M4 x 10 05 38 75 4 4 Fibre washer 17 x 10 2 x 0 5 mm 04 01 29 2 5 Countersunk head screw
87. et data operation are irreversible All changes made on the previous factory settings will be lost 510 03 36 rev 01 0 01 2002 service manual FPI 5000 I VERTICAL SYSTEM Folder settings System settings Service tests set def coll stop Note 2 The value of the counter Since installation see section 3 4 5 wont get lost during the data reset operation After pressing key 5 in figure 3 13 you see the text Please wait followed by Data cleared and Defaults installed Finally the photocell parameters are newly established The text Adjusting photocells appears In addition the displayed percentage indicates the progress of the adjustment process After completing the operation the menu of figure 3 5 will appear once again Background information The menu item Reset Data is part of the inserter menu This implies that only the FRAM of the inserter part of the SA 5005 system is cleared and initialized However this FRAM contains not only inserter related hardware settings but all the SA 5005 operational settings job information as well The other three types of FRAM in an SA 5005 system FPI 5000 C main board feeder boards and reading board contain only hardware related settings Intentionally clearing and initializing these FRAMs usually is not relevant from a service point of view Only in the case of FRAM memory failure the machine will use default FRAM data and therefore will newly establish the various hardwa
88. f the slotted photocell VSPH4 TP6D See also the BM digital inputs menu of section 3 3 3 e The green LED D303 and TP3D on the 5000 C base unit board 97 50 10 are reserved for the slotted photocell for the third fold table e A flashing green LED D101 on the feeder unit board 93 80 02 indicates correct operation of the local 97 50 13 software The normal flashing frequency is about 1 Hz If an error occurs the flashing frequency is about 4 Hz rev 01 0 01 2002 510 03 77 service manual FPI 5000 I 510 03 78 rev 01 0 01 2002 service manual FPI 5000 I Parts lists rev 02 0 02 2002 510 04 1 service manual FPI 5000 I 510 04 2 rev 02 0 02 2002 service manual Recommended spare parts FPI 5000 I Some of these parts already could be stocked being part of another recommended spare parts list Illustration Code nr Figure 510 04 6 36 Figure 510 04 8 28 61 Figure 510 04 12 24 36 40 45 Figure 510 04 16 56 Figure 510 04 20 10 36 Figure 510 04 24 10 11 Figure 510 04 28 15 66 Figure 510 04 32 7 22 25 Figure 510 04 34 7 12 39 02 0 02 2002 Description Moistening cloth Conductive bearing 10 mm Transportation roller 36 mm Transportation roller 30 mm Rubber roller 28 mm Led including holder Sensor including holder Transportation roller 2 30 mm Flagswitch Separation roller assy Upper sealing roller 36 mm Lower sealing ro
89. ftware for the FPI 5000 I FPI 5000 C combination 1s divided into three groups e inserter part currently the 5000 I inserter which will lead you to the menu of figure 3 5 e _ An FPI 5000 part for the feeding and folding subsystem which will lead you to the menu of figure 3 14 A general part that covers the combined 5000 5000 C system The accompanying system wide menu is shown in figure 3 24 In figure 3 1 a flowchart of the FPI 5000 I FPI 5000 C service software is shown The navigation through the service software is consistently the same for all menu items Pressing the Escape key will lead you to a one level higher level in the menu structure rev 01 0 01 2002 510 03 29 service manual FPI 5000 I MAIN MAIN MENU 1 2 MENU 2 MENU SERVICE MENU VERTICAL TOTAL SYSTEM SYSTEM PHOTOCELL FOLDER PHOTOCELL CONDITIONS SETTINGS CONDITIONS DFC DIGITAL SYSTEM DIGITAL RUN IN OMR CODE INPUTS SETTINGS INPUTS DEF ACTUATORS SERVICE READ LOCALI PAPER STOP TESTS CODE TEST SATION ACTUATOR JOB DOC OFF TESTS SETTINGS SET SECURE JOB INSERTER SEN SO RS SOFTWARE SYSTEM OUTPUT VERSIONS DISPLAY DFC SERVICE KEYBOARD TEST COUNTERS BRE RESET DATA OFFSET figure 3 1 Flowchart of the FPI 5000 I FPI 5000 C service software 510 03 30 rev 01 0 01 2002 service manual FPI 5000 I MAIN 1 MAIN 2 Other job JOB 1 Display contrast C
90. he paper photocell condition The screen of figure 3 7 provides real time information on the various paper photocells In this screen you also can see whether the relevant photocell sees paper The various photocells can be readjusted by pressing the Clear key The photocell adjustments are also automatically performed during each startup of the FPI 5000 I FPI 5000 C machines 510 03 32 rev 01 0 01 2002 service manual FPI 5000 I Note Before readjusting the photocell it is strongly recommended to remove all paper from the machines and to clean all the sensors both transmitter and receiver of the photocells After the photocell adjustments the percentages as shown in figure 3 7 should be lower provided the cleaning advice 1s heeded If no paper is present the photocell output voltage should have a value between 0 8 V and 1 3 V A value below this voltage range indicates a too heavily dusted photocell A value above this voltage range may occur if after readjusting a photocell dust is removed In both cases it is advised to readjust the photocells Normally the photocell current percentage lies between 10 and 50 This results in the message ok A percentage between 50 and 80 indicates the presence of dust and in an accompanying dust message If the photocell current percentage 1s higher than 80 an error message will be issued The only way to leave this menu is to press on the Escape key Key IH PHOTO COHDITIOH cur
91. he system output menu The PAPER STOP menu The DOCUMENT OFFSET menu The SECURE JOB menu The BRE offset menu The SERVICE COUNTERS menu The menu for readjusting the service counter Since installation The error screen for preventive maintenance rev 01 0 01 2002 FPI 5000 I 47 47 48 48 49 49 50 51 51 51 510 03 5 service manual FPI 5000 I 510 03 6 rev 01 0 01 2002 service manual FPI 5000 I Preliminary note The 5000 I is a dedicated vertical system inserter It is an integrated part of the SA 5005 folding and inserting machine The other integrated part of the SA 5005 system is the vertical feeding and folding unit FPI 5000 C The electrical description of the latter unit is discussed in document 520 02 rev 01 0 01 2002 510 03 7 service manual FPI 5000 I 1 Electrical and electronic operation The following illustrations belong to this chapter e Electrical electronic block diagram figure 1 1 on page 510 03 12 e General overview of the circuit boards and external items figure 1 2 on page 510 03 13 Overview main board 94 80 01 figure 1 3 on page 510 03 14 e Main board 94 80 01 1 power supply figure 1 4 on page 510 03 15 Main board 94 80 01 2 Photo electronics figure 1 5 on page 510 03 16 e Main board 94 80 01 3 CPU figure 1 6 on page 510 03 17 Main board 94 80 01 4 Drivers figure 1 7 on page 510 03 18 Main board 94 80 01 5 System
92. he washers 10 fitted on the two left hand side studs Replacement After retightening the four selflocking nuts check if all buttons 11 work properly When a button is pressed a click must be heard If no click 1s heard then slacken the selflocking nuts a little and check again 510 02 14 rev 01 0 01 2002 FPI 5000 I service QA UN VN VV simis W O TON figure 2 1 510 02 15 rev 01 0 01 2002 service manual FPI 5000 I 3 Main drive mechanism Remove the RH s de cover as described n paragraph 1 3 RH side cover 3 1 Chains 3 1 1 Short chain Removal Refer to figure 3 1 Slacken the two hex head screws 18 and release the chain tensioner 20 Take care not to loose the two plastic protection caps fitted on the threads of the two hex head screws Locate the chain connecting link on the chain 15 and release it Remove the chain from the sprockets 13 21 and 22 Take care of the sprocket 22 and the washer 19 on the chain tensioner Adjustment See paragraph 10 1 Short chain 3 1 2 Long chain Removal Refer to figure 3 1 Slacken the two hex head screws 2 and release the chain tensioner 1 Locate the chain connecting link on the chain 28 and release it Remove the chain from the sprockets 4 5 6 3 27 26 25 23 and 7 Adjustment See paragraph 10 2 Long chain 3 2 Clutch Removal Refer to figure 3 1 Disconnect the wiring of the clutch 34 Remove the s
93. iagnostic function e flashing green LED D314 on 5000 I main board indicates the correct operation of the 98 02 11 software The flashing rate 1s about 1 2 Hz e LED D222 on the FPI 5000 I main board indicates the optical condition of the receiver photocell of pulse disc PD1 translated into a digital value A rotating pulse disc causes D222 to be alternately on and off By pushing in the hand knob and turning it clockwise you can observe the blinking of D222 See also the digital inputs menu of section 3 2 1 5 3 FPI 5000 C feeder unit related error codes 5 3 1 Folder subsystem Error 2 10 Message Document stoppage Action Remove documents Info Stoppage at folder One or more documents jam in the folder subsystem Open the folder and remove the paper After pressing the Reset key the system returns to the stand by mode After pressing the Start key the processing of documents will resume Error 2 11 Message Document stoppage Action Remove documents Info Stoppage at folder The cam disc of the first fold table is temporarily out of synchronization This error replaces error 2 50 Error 2 12 Message Document stoppage Action Remove documents Info Stoppage at folder The cam disc of the second fold table is temporarily out of synchronization This error replaces error 2 51 Error 2 53 Message Document stoppage Action Remove documents Info Cover open rev 01 0 01 2002 510 03 65 serv
94. ice manual FPI 5000 I The upper part of the Eight in One subsystem containing the three upper green rollers and the fold table mechanisms is opened during the transport of paper Remove the paper close the cover and press the reset key Error 2 60 Message Sensor dusty Action Clean sensor Info none The relevant photocell VPH3 input of folding subsystem is dusty to such an extent that the full 100 of the photodiode current has been reached Readjust the photocell after cleaning with no paper present Error 2 61 Message Technical failure Action Call service Info Sensor fold in defective The photocell transmitter receiver combination of photocell VPH3 1s defective Check the wiring of both photocell parts Error 2 62 Message Technical failure Action Call service Info Sensor fold in defective The photocell transmitter LED of photocell VPH3 15 defective Check the wiring Error 2 63 Message Sensor dusty Action Clean sensor Info none Sensor needs readjustment after removed dust causes a too high LED current setting of the relevant photodiode Error 2 65 Message Sensor dusty Action Clean sensor Info none The relevant photocell VPH3 input of folding subsystem is dusty to such an extent that at least 80 of the photodiode current has been reached Compared with error 2 60 there is still a certain dust margin Readjust the photocell after cleaning with no paper present Error
95. il the left hand side clears the LH inside frame 28 Tilt the left hand side of the sealing roller in the front side direction and when possible withdraw it in the left hand side direction 8 2 Gear Gear 28T item 10 Removal Remove the lower sealing roller as described in the previous paragraph Refer to figure 8 1 Tap out the tension pin 22 Pull the bearing 12 from the sealing roller 7 special tool is required Slide the gear 10 off the sealing roller Take care of the washer 9 and the spacer 8 510 02 60 rev 01 0 01 2002 service manual FPI 5000 I 12 13 14 11 8 910 figure 8 1 rev 01 0 01 2002 510 02 61 service manual FPI 5000 I 9 Switches and detectors 91 Microswitches 9 1 1 Loc microswitch Removal Remove the RH s de cover as described n paragraph 1 3 RH s de cover 8 2 O A 4 figure 9 1 Refer to figure 9 1 Remove the round head screw 4 with washer securing the mounting bracket 6 After removing the nut 5 with washer and the two round head screws 1 with washers the microswitch 3 can be removed and disconnected Take care of the two insulating plates 2 on both sides of the microswitch Adjustment See paragraph 10 4 Microswitches 510 02 62 rev 01 0 01 2002 service manual FPI 5000 I 9 1 2 LH side cover microswitch Removal Remove the power supply cover as described in paragraph 1 8 Power supply cover figure 9 2 Refer to figure 9 2
96. in 4 Slide the gear 5 off the clutch shaft 21 Gear 15T item 12 Removal Refer to figure 4 5 Remove the clamping ring 14 and the washer 13 Slide the gear 12 off the bearing pin Take care of the spacer 8 Gear 28T item 6 Removal Withdraw the rubber roller 31 7 mm as described in paragraph 4 2 1 Rollers Refer to figure 4 4 Remove the two hex head screws 2 and securing the flapscraper 3 to the envelope guide 16 Withdraw the flapscraper Remove the four round head screws 1 securing the envelope guide to both inside frames Refer to figure 4 5 Pull the envelope guide aside so it is clear from the gear 6 Remove the clamping ring 19 and the washer 20 Slide the gear off the bearing pin Take care of the spacer 9 Adjustment See paragraph 10 9 Flapscraper Gear 15T item 11 Removal Refer to figure 4 5 Remove the two nuts 18 spring loaded Remove pressure spring 15 with the two washers 17 and the two spring holders 16 fitted on both sides Slide the gear 11 off the bearing pin Take care of the spacer 10 Adjustment See paragraph 10 8 Friction brake 510 02 38 rev 01 0 01 2002 service manual FPI 5000 I Gear 15T item 8 Removal Remove the rubber roller 28 mm as described in paragraph 4 2 1 Rollers Refer to figure 4 4 Tap out the tension pin 14 Slide the bearing 11 and the washer 10 off the roller axle 7 Tap out the tension pin 9 Slide the gear 8 off the roller axle
97. inch Remarks Self copying paper may cause rubber parts to wear quicker The rubber used in this machine has best resistance to Wiggins Teape material e The specification of the paper handling equipment is often wider than that of the envelopes and docu ments handled The condition of material handled will limit the specified environmental conditions We recommend that materials to be handled are stored at a temperature of 20 68 F with a relative humidity factor of 50 If difference in temperature occurs between store room and mailing area the material has to be stored near the machine at least 24 hours before use 510 00 8 rev 01 0 01 2002 service manual FPI 5000 I 3 Preparing the machine for use First the machine must be unpacked Then it must be mechanically and electrically hooked up with the FV 2A of which the paper processing configuration as a whole exists After unpacking and installing the machine 1s ready for use 3 1 Unpacking rev 01 0 01 2002 510 00 9 service manual FPI 5000 I 3 2 Unpacking instruction 510 00 10 rev 01 0 01 2002 4 service manual FPI 5000 I Preventive maintenance Recommended preventive maintenance checkpoints In the following it is assumed that if any unscheduled service call is less than a month prior to a preventive maintenance call it will replace that latter 1 2 3 IO 11 12 13 14 15 16 Ask how the machine has worked and use that i
98. installation Key A Preventive maintenance service O U AK U NM figure 3 36 The error screen preventive maintenance rev 01 0 01 2002 510 03 51 service manual FPI 5000 I 4 Test points All test points are located on the FPI 5000 I main board Supply carth Tel 35 V S Photo L ED TP207 current 1 V mm and no paper present PHI envelope TP201 Off no paper present HEN PHI envelope TP201 in On paper present PH2 flap TP202 Off no paper present detection PH2 flap TP202 On paper present detection document PH3 TP204 On paper present document 0 table 4 1 Off no paper present On paper present IV IV PH3 TP204 IV IV V Off no paper 5V On paper present Note I The test points TP102 TP301 and TP314 are not used for service purposes Note 2 The DFC output voltage is measured with no paper present 510 03 52 rev 01 0 01 2002 service manual FPI 5000 I 5 Error diagnosis and error codes The feeding and folding unit FPI 5000 C doesn t have its own user interface Therefore the error information on the FPI 5000 C base unit plus one two or three feeder units will be displayed on the FPI 5000 I control panel This information will be discussed here in addition to the FPI 5000 I related and system wide errors If an error occurs in one of the parts of the total SA 5005 system an error screen is displayed The l
99. ive memory The data checksum of the FRAM memory chip IC110 on the feeder unit board 93 80 02 1s not correct The FRAM settings for the paper photocells and the DFC unit are lost All documents must be removed from the machine Press the Reset key on the FPI 5000 I The paper photocells and the DFC unit will be readjusted Error 4 5 6 7 8 9 03 Message Technical failure Action Call service Info Defective memory Timeout error during access to the FRAM memory chip IC110 on the feeder unit board 93 80 02 The FRAM settings for the paper photocells and the unit are lost documents must be removed from the machine Press the Reset key on the FPI 5000 I The paper photocells and the DFC unit will be readjusted Error 4 5 6 7 8 9 05 Message Technical failure Action Call service Info Communication failure Checksum error during PC communication Error 4 5 6 7 8 9 06 Message Technical failure Action Call service Info Communication failure Wrong number of transmitted bytes during IPC communication Error 4 5 6 7 8 9 07 Message Technical failure Action Call service Info Communication failure rev 01 0 01 2002 510 03 73 service manual FPI 5000 I Wrong PC command Error 4 5 6 7 8 9 10 Message Feeding failure Action Remove documents Info Document too thick The document appears to be too thick or a double feed occurred D
100. l circuit is set at a too high value This message may be issued at startup during factory production testing or after field replacement of the photocell The photocell must be replaced by a more sensitive photocell Error 1 47 Message Technical failure Action Call service Info Exit sensor defective Photocell PH4 cannot be adjusted correctly The photodiode current resulting from the feedback control circuit is set at a too high value This message may be issued at startup during factory production testing or after field replacement of the photocell The photocell must be replaced by a more sensitive photocell Error 1 48 Message Track sensor dusty Action Clean sensor Info none During the process the photodiode of photocell is readjusted at a too low current resulting in too sensitive photocell This message may be issued at startup during factory production testing or after field replacement of the photocell The photocell must be replaced by a less sensitive photocell Error 1 49 Message Flap sensor dusty Action Clean sensor Info none During the process the photodiode of photocell PH2 is readjusted at a too low current resulting in a too sensitive photocell This message may be issued during factory production testing only or after field replacement of the photocell The photocell must be replaced by a less sensitive photocell Error 1 50 Message Loc sensor dusty Action Clean sensor Info
101. lacement Ensure on replacement that the two ejection rollers are refitted correctly on the ejection axle narrowing part of both rollers pointing inwards rev 01 0 01 2002 510 02 57 service manual FPI 5000 I EO RV S NET an KENNEN To 9 figure 7 1 510 02 58 rev 01 0 01 2002 service manual FPI 5000 I 7 2 Transportation rollers Open the loc as described in paragraph 1 1 Loc Open the LH hinged side cover as described in 1 4 LH hinged side cover Set of sealing track transportation rollers 30 mm Removal Remove the long chain as described in paragraph 3 1 2 Long chain Remove the pulse disc as described in paragraph 3 5 2 Sprockets Long chain Refer to 7 2 Push the two transportation rollers 1 in the right hand side direction from the cyl pins below Remove the two cyl pins from the transportation axle 2 Remove the spring clip 23 the washer 24 and the bearing 25 Withdraw the transportation axle in the right hand side direction out of the machine and slide the two transportation rollers off it Take care of the bearing 3 the spacer 4 and the washer 5 Replacement Ensure on replacement that the two transportation rollers are refitted correctly on the transportation axle narrowing part of both rollers pointing in the left hand side direction rev 01 0 01 2002 510 02 59 service manual FPI 5000 I 8 Envelop sealing and ejection Open the loc as described in paragraph 1 1 Loc
102. lectronics cover on the rear side Carefully lift the electronics cover upwards Take care of the wiring Disconnect the wiring of the electronics cover at the mainboard 18 and withdraw the electronics cover Replacement Ensure on replacement that the front side of the electronics cover is fitted between the guide spring 18 and the front cover plate 17 1 6 Cover plate Open the loc as described in paragraph 1 1 Loc Remove the RH side cover as described in paragraph 1 3 RH side cover Remove the electronics cover as described in previous paragraph Removal Refer to figure 1 1 Remove the two round head screws 9 and the two nuts 15 securing the cover plate 8 Remove the cover 7 Lift and withdraw the cover plate upwards 1 7 Front cover plate Removal Refer to figure 1 1 Hold the guide spring 18 and the front cover plate 17 in place Remove the two countersunk screws 19 Remove the guide spring and withdraw the front cover plate from behind the front side of the electronics cover 12 Replacement Ensure on replacement that the front cover plate 15 fitted behind the front side of the electronics cover 1 8 Power supply cover Removal Open the LH hinged side cover as described in paragraph 1 4 LH hinged side cover Remove the electronics cover as described in paragraph 1 5 Electronics cover Refer to figure 1 1 Unplug the power supply lead from the mains switch Remove the two countersunk screws 24 sec
103. ll remains covered too long Remove the paper After pressing the Reset key the system returns to the stand by mode After pressing the Start key the processing of documents will resume Error 3 11 Message Document stoppage Action Remove documents Info Stoppage at collator This error message is generated 1f VPH2 the photocell that guards the entry of the collator area remains covered too long Remove the paper After pressing the Reset key the system returns to the stand by mode After pressing the Start key the processing of documents will resume Error 3 12 Message Document stoppage Action Remove documents Info Stoppage at collator This error message 1s generated if it lasts too long for documents that leave the collator area to reach the folding are input photocell VPH3 Remove the paper After pressing the Reset key the system returns to the stand by mode After pressing the Start key the processing of documents will resume Error 3 13 Message Document stoppage Action Remove documents Info Stoppage at divert This message 1s generated if in the case of multifeeding a timing error around the processing of a partially completed set to and from the shunt area occurs Remove the paper After pressing the Reset key the system returns to the stand by mode After pressing the Start key the processing of documents will resume Error 3 14 Message Technical failure Action Remove documents Info Stoppage at co
104. llator This error occurs if at the start of the machine or after a change to a new job paper is present in the collator area and if no divert subsystem is present The divert area is not only used to divert double feed affected sets from the main document stream but it is used as well for automatically emptying the vertical track and the collator area from paper during the start of the machine or after a job change If no divert area 1s present this paper must be removed manually Error 3 20 Message System not ready Action Remove all documents 510 03 68 rev 01 0 01 2002 service manual FPI 5000 I Info Documents n system The vertical system is not empty in any situation where a machine is supposed to be clear from paper Remove the paper After pressing the Reset key the system returns to the stand by mode After pressing the Start key the processing of documents will resume Error 3 21 Message Empty feeders Action Load documents Info none feeders are empty Refill one or more feeders Error 3 50 Message Technical failure Action Call service Info Communication failure The PC communication between feeder unit 1 feeders 1 and 2 and the FPI 5000 C base unit fails This error is also generated during system initialisation if the FRAM data supposes this unit to be present but it appears to be removed Error 3 51 Message Technical failure Action Call service Info Communication failure
105. ller assy 36 mm Pulse disc sensor assy Microswitch Pulse disc Clutch CW clockwise 8 mm Drive belt PJ L 813 mm Gear 17T Transportation roller 31 7 mm Feed roller 2 42 mm Part code Number 04 03 06 04 24 26 76 04 66 04 18 27 73 28 93 04 24 52 04 24 53 46 04 56 02 10 76 95 71 03 73 26 48 04 23 13 82 16 22 12 12 22 24 12 81 12 14 63 04 15 57 24 11 67 76 04 65 73 27 31 Stock qty per number of installed machines 1 10 100 1 2 4 1 1 2 2 2 10 1 1 2 2 2 4 2 2 4 4 4 8 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 2 4 1 1 2 510 04 3 Figure 510 04 38 8 9 18 40 44 Figure 510 04 42 A Figure 510 04 47 35 44 Figure 510 04 50 23 24 36 49 510 04 4 service manual Eprom Mainboard Unit motor transformer board Unit F RAM 2K LCD Keyboard Solenoid Damper Transportation roller 42 5 mm Brush holder Brush Transportation roller 38 mm Timing belt 98 02 11 94 80 01 12 16 21 95 74 55 95 70 72 12 12 87 03 11 90 73 25 76 46 04 60 72 00 05 76 04 67 04 15 37 OV WW m FPI 5000 I 1 2 1 2 1 1 1 1 1 2 2 4 1 1 2 4 1 1 3 6 6 6 1 2 rev 02 0 02 2002 service manual FPI 5000 I rev 02 0 02 2002 510 04 5 service manual FPI 5000 I 12 13 14 15 16 17 18 30 29 28 27 26 25 24 23 33 32 31 Figure 1 510 04 6 rev 02 0 02 2002 service manual FPI
106. m the machine readjustment of paper photocells Error 1 5 Message Technical failure Action Call service Info Memory failure During the reading from or writing to FRAM a checksum error occurs Default values will be used in stead of FRAM based values Remove all paper from the machine readjustment of paper photocells Error 1 9 Message Technical failure Action Call service Info Hardware failure Error 1 10 Message Envelope too long Action Remove envelope Info Envelope length error Envelope too long Remove the envelope from the envelope track A too long closed envelope is longer than 162 mm 20 mm tolerance 182 mm A too long opened envelope is longer than 162 mm 130 mm flap length 20 mm tolerance 312 mm Error 1 11 Message Document stoppage Action Remove documents Info Inserting failure Inserting error The document input photocell PH3 remains covered too long Remove the envelope and the document from the insert table The maximum document length is about 40 cm Error 1 12 Message Document stoppage 510 03 54 rev 01 0 01 2002 service manual FPI 5000 I Action Remove documents Info Document length error Change in document length The document input photocell 15 covered too long or too short Remove envelope and the document from the insert table This message is displayed if the document is about 40 mm or more shorter or longer than the reference length If as yet
107. n document detector PH3 detects the trailing edge of the document set Then a number of actions take place a clutch RPMI is activated to release the flap b solenoid So2 is shortly activated resulting in the ejection roller in the loc moving down By spring action after switching S02 off this driven roller is pulled high again Now the envelope is rejected from the insert table S02 1s deactivated after the complete passage of the filled envelope Also by activating a new envelope 15 transported to the insert table The filled envelope passes the lowered brushes The envelope passes the second eject rollers and the sealing track rollers On a certain time the leading envelope edge triggers flag switch FS1 Now a pulse count is started The envelope passes the sealing transport roller lower sealing roller combination rollers 27 and 30 Flag switch FS is restored to its rest position after the trailing envelope edge has passed The upper reverse roller is held high i e this roller doesn t contact the lower reverse roller by a spring After a time determined by the FS1 triggered pulse count So4 1s activated The envelope is between the upper and lower reverse rollers By the So4 action the upper reverse roller now is temporarily lowered Given the turning direction of the lower reverse roller 28 which also transmits mechanical drive to the loc the transport direction of the envelope is abruptly changed from see foldout on
108. n springs 9 from the thread of the round head screw 23 Remove the two round head screws 25 from both sides of the loc frame Refer to figure 6 4 Carefully withdraw the cradle from between the frame Take care of the spacer 1 and the two washers 14 Slide the axle 11 out of the cradle and withdraw the gear 8 Take care of the bearing 2 the spacer 5 the washer 6 and the spacer 7 on the left hand side of the gear and of the bearing 13 and the spacer 10 and 9 on the right hand side of the gear 510 02 50 rev 01 0 01 2002 service manual FPI 5000 I figure 6 4 Gear 15T item 22 Removal Remove the gear 20T item 8 as described in previously Refer to figure 6 4 Remove the set screw and slide the roller 27 off the axle 18 Remove the pressure springs 25 and 15 Remove the two round head screws 3 and withdraw the bearing plate 4 Take care of the bearing 26 Remove the spacer 24 and the two washers 13 from the bearing pin 12 Slide the gear 22 off the bearing pin Take care of the spacer 19 Replacement When retightening the set screw ensure that there 1s only a slight amount of axial play on the axle Gear 15T item 21 Removal Remove the gear IST item 22 as described in previously rev 01 0 01 2002 510 02 51 service manual FPI 5000 I Refer to figure 6 4 Tap out the tension pin 20 Slide the gear 21 off the axle Replacement When retightening the set screw ensure that there is only a slight amount of axi
109. n the bracket carrying the lower insert roller must be reset slightly to obtain the correct condition at each point Repeat this check across the second lower insert roller on the transportation table 510 02 80 rev 01 0 01 2002 service manual FPI 5000 I 10 11 Upper insert rollers loc IX 2 N TS NN 4 D bL CP 4 lt 2 d figure 10 11 Refer to figure 10 11 The upper insert rollers are mounted into a moveable cradle 3 The cradle 15 kept in the lowest position by two springs 4 Documents up to 1 5 mm 0 06 inch thick are inserted under the pressure of the two springs but those in excess of 1 5 mm are also subjected to the pressure of the pressure springs 5 The first 1 5 mm of lift 1s adjusted by repositioning the cradle stop axle 2 mounted above the roller cradle carrying the upper insert rollers To adjust Remove the loc cover as described in paragraph 6 1 Covers and plates Raise the loc to the vertical position as described in paragraph 1 1 Loc Slacken the two hex head screws 1 securing the cradle stop axle 2 Position the cradle stop axle so that it stops the movement of the roller cradle 3 when the rollers are lifted 1 5 mm above the insert rollers below Retighten the two hex head screws and check the adjustment rev 01 0 01 2002 510 02 81 service manual FPI 5000 I 510 02 82 rev 01 0 01 2002 service manual FPI 5000 I El
110. n the plunger Adjustment See paragraph 10 5 Solenoids rev 01 0 01 2002 510 02 53 service manual FPI 5000 I 6 4 Envelope transport and sealing 6 4 1 Rollers Second set of upper ejection rollers 38 mm Remove the loc cover as described in paragraph 6 1 Covers and plates Open the loc as described in paragraph 1 1 Loc Removal Refer to figure 6 7 Grab the brush holder 18 across the narrow part adjacent to the rollers 13 and 17 and while turning it sideways pull it outwards from behind the lip of the leaf spring 19 Slacken the set screws of the rollers 13 and 17 and slide them off the axle 15 Take care of the bearing 14 and 16 with the pressure springs Replacement Ensure on replacement that the set screws rest in the grooves of the axle The rollers must have an axial play of approx 1 mm 0 04 inch to ensure independent movement of the right and left hand roller Set of sealing transport rollers 38 mm Removal Refer to figure 6 7 Remove the spring clip 1 the washer 2 and the spacer 3 Slide the roller 4 off the axle 7 Take care of the spacer 5 Take care of the bearing 6 with the pressure spring Slacken the set screw of the roller 10 Remove the spring clip 12 and the spacer 11 Slide the roller 10 off the axle 7 Take care of the spacer 9 Take care of the bearing 8 with the pressure spring Replacement Ensure on replacement that the left hand side roller 4 1s the one that is free ru
111. nds of auxiliary functions for instance the bank switching of four different 32 kilobyte parts of the EPROM This enables more than the 64 kilobytes of code memory to be used than what the CPU can address with its 16 address lines The CPU has an PC bus for both on board and external communication This bus consists of the serial data line SDA and the serial clock line SCL The SCS concept is based on the PC bus In fact there are two PC buses in addition to the SCS PC bus a simulated bus 1s used This bus is made of port bits P4 0 SCL SIM and P4 1 SDA SIM The simulated bus 1s used for less time critical local domestic issues such as control of the DFC and photocell DACs and access to the FRAM and control panel boards Main board power supply A transformer supplies an AC voltage of some 30 volt This voltage 1s rectified and smoothed by three parallel operating bridge rectifiers and buffer capacitors Two groups 24V I and 24V are used for the supply of external predominantly upstream devices They are available on the 12 pole system connector Voltage regulators provide a stabilized 5 V voltage VDD for the digital chips U100 and a stabilized 15 V voltage U120 that 1s further stabilized to 12 V by U231 to supply the DAC chip U230 and dual operational amplifier U210 A fourth voltage regulator U130 ANA 5V supplies the reference voltage AVDD for the A D converter in the CPU and the base voltages for the DAC reference and the DFC offse
112. nfo Document too early Wrong timing of insertion of the document Remove the document from the insert table Between the ejecting of the filled envelope and the placing of a new envelope on the insert table including the fingers moved in that envelope no document may be present under the document photocell PH3 In the fold only mode of the FPI 5000 I also without envelopes involved a new document is not allowed to cover PH3 before the previous document has been ejected and a new document call has been issued Error 1 18 Message Document stoppage Action Remove documents rev 01 0 01 2002 510 03 55 service manual FPI 5000 I Info Inserting failure The loc is opened or PH3 covered at the time at which a document call is issued Close the loc or remove the PH3 covering paper Error 1 19 Message Envelope stoppage Action Remove envelope Info Flap sensor covered The flap photocell PH2 15 covered too long Remove the envelopes from the envelope track if necessary by turning the hand knob until the envelopes reach the insert table Error 1 20 Message Envelope stoppage Action Remove envelope Info Envelope lost The envelope position is unknown to the machine flashes Remove the envelopes from the envelope track if necessary by turning the hand knob until the envelopes reach the insert table This error can occur if the machine has been stopped during feeding an envelope to the insert table by opening a cover or
113. nformation as a guide for checking the equipment Ask f there has been change in use of the machine such as high production or change of material Check the machine adjustments and check materials and if necessary instruct the operator s again Many service calls are caused by wrong adjustments or wrong material and sometimes there is a quick succession of operators Here a five or ten minutes refresher course would save unnecessary and embarrassing service calls in the future Test the proper functioning of the safety switches of the transparent cover and the hinged cover Check condition of the separation roller adjust or replace if necessary Check the adjustment of the joggers adjust 1f necessary Check the envelope stop position on the insert table About 2 mm 0 08 inch maximum variation accepted If more clean lower track photocell check clutch functioning check flapscraper adjustment and friction break adjustment and functioning Check if the envelope flap is correctly held at the insert place Check the pressure of the upper insert rollers on the documents adjust if necessary Check the moistening brushes and moistening cloth Wash out the brushes and if necessary instruct the operator to wash out the brushes regularly Check the moistening cloth and replace if more than 120 000 inserts have been made Check the tension and the adjustment of the chains and the main drive belt adjust or replace if necessary Check the c
114. nk RH side cover LH hinged side cover Electronics cover Cover plate Front cover plate Power supply cover Base cover Transportation table Front cover Insert table Feed platform Rear cover Electrical components Power supply unit Mainboard and small PCB Control panel Main drive mechanism Chains Short chain Long chain Clutch Main drive belt Pulleys Sprockets Sprockets short chain Sprockets long chain Gears Motor Envelope feed Hopper O rings Rollers Gear FPI 5000 I Page 00 00 00 10 10 10 11 11 12 12 13 13 14 14 14 14 16 16 16 16 16 18 18 20 20 20 22 24 28 28 28 29 29 510 02 3 510 02 4 4 2 4 2 1 4 2 2 4 2 3 5 1 32 5 3 6 1 6 2 6 2 1 6 2 2 6 2 3 6 3 6 3 1 6 3 2 6 3 3 6 4 6 4 1 6 4 2 7 1 7 2 8 1 8 2 9 1 9 1 1 9 1 2 9 1 3 9 2 2 9 9 4 9 4 1 9 4 2 9 4 3 9 4 4 service manual Envelope track Rollers Gears Clutches Document feed Upper transportation rollers Lower transportation rollers Finger solenoid Loc Covers and plates Drive mechanism Main drive belt Pulleys Gears Document inserting Rollers Gears Ejection solenoid Envelope transport and sealing Rollers Solenoid Envelope transport Lower ejection rollers Transportation rollers Envelop sealing and ejection Sealing rollers Gear Switches and detectors Microswitches Loc microswitch LH side cover micro
115. nning When retightening the set screw of the roller 10 ensure that rollers have an axial play of approx 1 mm 0 04 inch to ensure independent movement of the right and left hand roller Set of lower reverse rollers 36 mm Removal Remove the pulley 14T item 5 as described in paragraph 6 2 2 Pulleys Refer to figure 6 2 Slacken the set screw of the roller 8 and slide it off the axle 7 Take care of the bushing 9 the washer 13 and the bearing 12 510 02 54 rev 01 0 01 2002 service manual FPI 5000 I o 7 101112 1234 56 figure 6 7 rev 01 0 01 2002 510 02 55 service manual FPI 5000 I Set of upper reverse rollers non driven Remove the top cover as described in paragraph 6 1 Covers and plates Removal figure 6 8 Refer to figure 6 8 Remove the spring clips 8 and the washers 9 from both sides of the bracket 12 Slide the two rollers 10 off the bearing pins 11 6 4 2 Solenoid Sealing solenoid Remove the top cover as described in paragraph 6 1 Covers and plates Removal Refer to figure 6 8 Disconnect the wiring of the solenoid coil 3 Remove the two round head screws 1 with the washers 2 securing the solenoid coil Slide the solenoid coil from the plunger 6 attached to the draw bar 7 and withdraw it Take care of the two washers 4 and the pressure spring 5 on the plunger Adjustment See paragraph 10 5 Solenoids 510 02 56 rev 01 0 01 2002 service manual FPI 5
116. no reference length is taken only error 11 for a too long document may apply Error 1 13 Message Envelope stoppage Action Remove envelope Info Transport failure Exit photocell PH4 remains covered too long Remove the envelopes from the exit table The too long criterion amounts to a length of about 35 cm Error 1 14 Message Document stoppage Action Remove documents Info Document too thin The document is thinner than the reference thickness Remove the envelope and the document from the insert table This error message i1s issued if the document is more than 40 micrometer thinner than the reference thickness A 45 g per cm sheet of paper has a thickness of about 50 micrometer This error message only is issued if the DFC function is activated and if the reference thickness is known See also error 28 Error 1 15 Message Envelope stoppage Action Remove envelope Info Flap not opened The envelope has no flap at all or its flap 1s not properly opened Remove the envelope from the insert table This error message i1s relevant for the machine operating in the seal envelopes mode Error 1 16 Message Envelope stoppage Action Remove envelope Info Transport failure Filled envelope didn t arrive at the exit photocell The sealing stage takes too much time the exit photocell PHA is not reached in time Remove the paper from the exit Error 1 17 Message Document stoppage Action Remove documents I
117. nu FV PHOTO CONDITION In the FPI 5000 I and FPI 5000 C so called intelligent photocells are used This implies that within a certain control range the currents of the photocell transmitters are adjusted in such a way that the no paper output voltage of the photocell receiver falls within a certain voltage range of the photocell receiver In this way fair amounts of dust present on the photocell sensors are compensated for The control mechanism ensures that very reliable paper no paper decisions are being made based on the paper photocell condition The screens of figure 3 18 provide real time information on the various paper photocells In this screen you also can see whether the relevant photocell sees paper The various photocells can be readjusted by pressing the Clear key The photocell adjustments are also automatically performed during each startup of the FPI 5000 I FPI 5000 C machines Note Before readjusting the photocell it is strongly recommended to remove all paper from the machines and to clean all the sensors both transmitter and receiver of the photocells After the photocell adjustments the percentages as shown in figure 3 18 should be lower provided the cleaning advice 1s heeded If no paper is present the photocell output voltage should have a value between 0 8 V and 1 3 V A value below this voltage range indicates a too heavily dusted photocell A value above this voltage range may occur if after readjusting a photocell du
118. nual FPI 5000 I 1 Covers and plates 1 1 Loc Opening Refer to figure 1 1 Pull the blue locking lever on the left hand s de of the loc 10 upwards to release it Lift the loc upwards and place it straight up in the vertical position 1 2 Water tank Removal Refer to figure 1 1 Pull the topside of the LH side cover 32 in the left hand side direction to release it Place it flat in the horizontal position Take care not to wedge the power supply lead Pull the water tank 1 in the left hand side direction and withdraw it 1 3 RH side cover Removal Refer to figure 1 1 Remove the round head screws 13 Move the RH side cover 14 to the back side direction and unhook the cover 14 1 4 LH hinged side cover Opening Refer to figure 1 1 Pull the topside of the LH side cover 32 in the left hand side direction to release it Place it flat in the horizontal position Take care not to wedge the power supply lead Removal Refer to figure 1 1 Remove the two strips 29 Remove the three cap nuts 28 and the washers and withdraw the LH cover 32 510 02 8 rev 01 0 01 2002 FPI 5000 I service 23 22 21 20 31 30 29 32 figure 1 1 510 02 9 rev 01 0 01 2002 service manual FPI 5000 I 1 5 Electronics cover Removal Refer to figure 1 1 Slacken the two countersunk head screws 19 securing the electronics cover 12 on the front s de Remove the two round head screws 11 with washers securing the e
119. o clean both sensors of PH2 and to readjust this photocell Error 1 66 Message Loc sensor dusty Action Clean sensor Info none Dust warning for photocell PH3 There is still a dust margin available but it is advised to clean both sensors of PH3 and to readjust this photocell Error 1 67 Message Exit sensor dusty Action Clean sensor Info none Dust warning for photocell PHA There is still a dust margin available but it is advised to clean both sensors of PHA and to readjust this photocell Error 1 80 Message No connection Action Check device connector Info Communication failure CRC error at receiving mail via PC communication Error 1 81 Message No connection Action Check device connector Info Communication failure PC delivered mail not accepted by the FPI 5000 C Error 1 82 Message No connection Action Check device connector Info Communication failure 510 03 62 rev 01 0 01 2002 service manual FPI 5000 I Command unknown by slave Error 1 83 Message No connection Action Check device connector Info Communication failure The FPI 5000 C doesn t accept the command Error 1 84 Message No connection Action Check device connector Info Communication failure Command not identified by the FPI 5000 Error 1 85 Message No connection Action Check device connector Info Communication failure The FPI 5000 I cannot communicate properly by SCS
120. ocation of the error is indicated by an IM or BM icon There are three kinds of errors e Hardware errors The error screen displays a call service icon e Hardware related errors and warnings for which the operation of the machine can be continued flow errors The error screen consists of exclamation icon followed message A hand icon is followed by a suggested action With the info key 1 1 additional information is displayed including an error code number as long as this key 1s pressed After pressing the Reset key 6 either the main menu is entered from which the service menu can be entered or the system will be reset to the normal operational condition provided the problem that initiated the error message has been solved The error code number is preceded by a number that indicates the location of the error The error format is as follows X YYY X is a prefix number between and 9 Y is error number proper The meaning of the prefix number is as follows 1 FPI 5000 I part of the SA 5005 2 Eight in One folding subsystem of 5000 3 The vertical transport system of the FPI 5000 C including the collator and shunt area Divert amp Go area control Feeder 1 the lower feeder of feeder unit 1 Feeder 2 the upper feeder of feeder unit 1 Feeder 3 the lower feeder of feeder unit 2 Feeder 4 the upper feeder of feeder unit 2 Feeder 5 the lower feeder of feeder unit 3 Feeder 6 the u
121. oesn t mach the SA 5005 Eprom set or hasn t the same revision level Error 3 91 Message Technical failure Action Call service Info Update Feederl 2 SW The software for the feeder module for the lower two feeders has not the same revision level as the other SA 5005 software Error 3 92 Message Technical failure Action Call service Info UPDATE Feeder 3 4 SW The software for the feeder module for the middle two feeders has not the same revision level as the other SA 5005 software Error 3 93 Message Technical failure Action Call service Info UPDATE Feeder 5 6 SW The software for the feeder module for the upper two feeders has not the same revision level as the other SA 5005 software 510 03 72 rev 01 0 01 2002 service manual FPI 5000 I 5 3 3 Feeder subsystem Error 4 5 6 7 8 9 00 Message Empty feeder Action Load documents Info none Error 4 5 6 7 8 9 01 Message Technical failure Action Call service Info Defective memory The FRAM memory chip IC110 on the feeder unit board 93 80 02 doesn t acknowledge access by the FPI 5000 C base unit software The FRAM settings for the paper photocells and the DFC unit are lost AII documents must be removed from the machine Press the Reset key on the FPI 5000 I The paper photocells and the DFC unit will be readjusted Error 4 5 6 7 8 9 02 Message Technical failure Action Call service Info Defect
122. of photocell VPHI is defective Check the wiring 510 03 70 rev 01 0 01 2002 service manual FPI 5000 I Error 3 64 Message Vert tr sensor dusty Action Clean sensor Info none Sensor needs readjustment after removed dust causes a too high LED current setting of the relevant photodiode Error 3 65 Message Vert tr sensor dusty Action Clean sensor Info none The relevant photocell vertical track photocell VPH1 is dusty to such an extent that more than 80 of the photodiode current has been reached Compared with error 3 61 there is still a certain dust margin Readjust the photocell after cleaning with no paper present Error 3 70 Message Technical failure Action Call service Info Motor failure The collator motor is checked via its accompanying pulse disk and slotted photocell VSPH4 Provided VSPHA is correctly operating see the service software this motor is probably defective Error 3 71 Message Collator sensor dusty Action Clean sensor Info none The relevant photocell collator area input photocell VPH2 is dusty to such an extent that the full 10096 of the photodiode current has been reached Readjust the photocell after cleaning with no paper present Error 3 72 Message Technical failure Action Call service Info Collator sensor defective The photocell transmitter receiver combination of photocell VPH2 15 defective Check the wiring of both photocell parts Erro
123. of the insert table together with the finger 4 in the middle upwards Shift the insert table in the front side direction and when possible withdraw it in the left hand side direction Take care of the finger in the middle and the knurled knobs 3 on the outer four fingers Replacement Refer to figure 1 1 Ensure on replacement of the insert table 3 that the rear side of it 1s placed on top of the guide plate 6 510 02 12 rev 01 0 01 2002 service manual FPI 5000 I 1 13 Feed platform Remove the RH s de cover as described n paragraph 1 3 RH s de cover Open the LH hinged s de cover as described n paragraph 1 4 LH hinged s de cover Removal Refer to figure 1 1 Unhook the envelope slide 5 and withdraw it Pull the envelope receiving tray 4 in the rear side direction and withdraw it figure 1 3 Refer to figure 1 3 Pull the bellow 5 upwards and withdraw it Remove the two countersunk screws 2 securing the rear cover 3 Remove the round head screws 7 securing the feed platform 1 on both sides to the inside frames 6 Lower the rear side of the feed platform downwards and withdraw it in the rear side direction Take care of the rear cover 1 14 Rear cover Removal Remove the feed platform as described in the previous paragraph Refer to figure 1 3 Pull the rear cover 3 downwards from behind the frame rod 4 and withdraw it 1n the rear side direction rev 01 0 01 2002 510 02 13 service manual FPI
124. on bearing 8 mm Locking rod Rubber stop Locking strip Sleeve Inside frame loc Round head screw MA x 8 Buffer assy Fibre washer 0 12 x O 4 2 x 1 mm Guide block 98 00 13 05 38 69 12 14 89 12 12 87 45 43 11 45 37 45 03 35 52 43 59 19 05 24 63 05 24 46 04 01 40 84 17 04 04 09 05 73 41 76 23 47 77 43 50 17 43 50 16 98 00 14 45 19 02 95 72 54 45 37 43 95 72 56 08 28 33 05 33 22 24 09 36 04 24 26 04 01 43 13 31 51 05 24 31 45 38 75 98 00 31 45 38 71 13 3133 24 12 29 03 11 14 04 09 34 03 12 02 04 09 05 73 34 65 04 12 16 43 34 57 45 38 68 83 34 97 04 01 21 04 11 76 e LO BR N e A hA me e me N DW ON BRR N N mm e HM MH O 510 04 43 Figure 510 04 42 Remarks 510 04 44 illustration code number 46 47 48 49 service manual Description Washer 7 x 3 2x 0 5 mm Pan head tapping screw Round head screw MA x 8 Cross bar FPI 5000 I Part code Quantity Remarks number FPI 5000 I 45 37 39 45 38 53 45 43 13 93 12 93 N rev 02 0 02 2002 service manual FPI 5000 I rev 02 0 02 2002 510 04 45 service manual FPI 5000 I 11 12 13 14 15 16 A 5 9 2 2 4 NR 2 9 EIN ME 2 5 i S A 4 34 33 32 31 bl 43 42 41 40 39 38 37 36 35 Figure 12 510 04 46 rev 02 0 02 2002 service manual FPI 5
125. on from the cyl pins below Remove the two cyl pins from the transportation axle 13 Remove the spring clips 10 from both sides of the transportation axle Withdraw the transportation axle in the right hand side direction out of the machine and slide the two transportation rollers off it Take care of the washers 16 and bearings 18 on both sides Replacement Ensure on replacement that the two transportation rollers are refitted correctly on the transportation axle narrowing part of both rollers pointing in the left hand side direction 510 02 42 rev 01 0 01 2002 service manual FPI 5000 I Second pair of transportation rollers 36 mm Removal Refer to figure 5 2 Push the left hand transportation roller 14 inwards from the cyl pin below Remove the cyl p n from the transportation axle 15 Remove the spring clips 11 from both sides of the transportation axle Slide the transportation axle approximately 15 mm 0 6 inch in the right hand side direction Take care of the washer 177 and the bearing 19 Hold the axle and push the right hand transportation roller 4 inwards from the cyl pin below Remove the cyl pin from the transportation axle Withdraw the transportation axle in the right hand side direction out of the machine and slide the two transportation rollers off it Take care of the washer 8 and the bearing 9 Replacement Ensure on replacement that the two transportation rollers are refitted correctly on the transport
126. ondition of the rubber rollers and the freewheel clutch clean or replace 1f worn Check the condition of the sprockets pulleys and gears replace if necessary Check the adjustment of the solenoids adjust 1f necessary Remove paper dust from photocells LEDs and receivers Test the system hardware and software using the service software If available make a test run with users material if not use own material for the test run rev 01 0 01 2002 510 00 11 service manual FPI 5000 I 510 00 12 rev 01 0 01 2002 service manual FPI 5000 I Process description rev 01 0 01 2002 510 01 1 service manual FPI 5000 I 510 01 2 rev 01 0 01 2002 rev 01 0 01 2002 2 1 22 2 3 service manual Contents Section Overview Some details Envelope transport Document input and insert Envelope ejecting sealing and exiting FPI 5000 I Page oo NN 510 01 3 service manual FPI 5000 I 510 01 4 rev 01 0 01 2002 service manual FPI 5000 I 1 Overview The FPI 5000 I inserter performs the following tasks Transport an empty envelope from the hopper to the insert position 2 Transport a single document or document set from the FPI 5000 C to and in the opened envelope 3 Eject and seal the filled envelope and transport it to the rear exit or side exit The simplest diagram of this process consists of just three arrows These three tasks make up just one cycle of the machine operating in
127. or Envelope transport Sol 504 MI clutch 1 So2 figure 1 1 Electrical electronic FPI 5000 I block diagram 510 03 12 rev 01 0 01 2002 FPI 5000 I service manua YOSSADIDV 13TOIA YOLOW p UM 190 aNod OAS HOLOW T66ZE8 ASSY NWL SSVYLS6 UIAODIGIS SW O I V S 9 Z 80a III 005 NOLWDINNWWOD qvas Hd XL 201 c 05 v OS 60STCT An 12313 DNIIVYS 80SICI oyna ecSsvcvo GION3IOS GION3IOS vsn 4915193345 AALNN OD HdAL 9 Md 113 JH 95054 SNIVIA trt HOLIMS SNIVIA 6rSTZT AOTT SJAMDNI VE AOZZ HdAL 3505 LAN 11 YAM Od 008 6 1 35 NI QGHVOSNIVIN 00 r o in st mam Sv S86 9NIHIM 0ZOILZ ZLOLS6 QquvOogsA3 d21 86 1 0005 143 TTT68L9S7VECT B L 9 6 P E CI 9LOTZO ONMV3S 05 GIONTIOS THd XLAN3 DN csvcvo GEGLEL IA 1 O Z SIN XLdV14 V 1471128 YA Xu dvd SvcvO Hd 201 TLIIZ8 AA A Xu ANY 2SIG ISINd Hd ANA XL LIX3 c 1128 AA YR Xu LIX3 1005 ternal connect ts including ex IC
128. ote Do not adjust the chain too tight rev 01 0 01 2002 510 02 71 service manual FPI 5000 I 10 2 Long chain oXo oXo oXo oXo oXo oXo oXo oXo oXo oXo oXoro 9 pO R 7 LH IE I IEICIEIEIEI IEIEICICHEICHEIEIEIE IME DE DE DEDEDE DEDE DEDEDE III 10 15 mm 0 4 0 6 inch figure 10 2 Refer to figure 10 2 The maximum movement of the chain at the indicated position is 10 15 mm 0 4 0 6 inch To adjust Remove the RH side cover described in paragraph 1 3 RH side cover Slacken the two hex head screws 1 securing the chain tensioner 2 Shift the chain tensioner to adjust the correct chain movement Hold the chain tensioner in position and retighten the two hex head screws Check the adjustment and readjust if necessary Note Do not adjust the chain too tight 510 02 72 rev 01 0 01 2002 service manual SA IFPI 5000 IN 10 3 Main drive belt 10 mm 0 4 inch figure 10 3 Refer to figure 10 3 The maximum movement of the drive belt at the indicated position is 10 mm 0 4 inch To adjust Remove the RH side cover described in paragraph 1 3 RH side cover Slacken the two hex head screws 1 securing the belt tensioner 2 Shift the belt tensioner to adjust the correct belt movement Hold the belt tensioner in position and retighten the two hex head screws Check the adjustment and readjust if necessary Note Do not adjust the drive belt too
129. ounters 0 Job menu Fill amp Start figure 3 2 The two part MAIN MENU Key JOB ACCESS 1 2 Enter pin code 3 ri 4 5 6 figure 3 3 The menu JOB ACCESS SERVICE MEHU Inserter Vertical system Total system figure 3 4 The main SERVICE MENU rev 01 0 01 2002 510 03 31 service manual FPI 5000 I 3 2 The INSERTER service software The menu consists of s x submenus as shown n figure 3 5 The submenus are Sensors figure 3 6 DFC figure 3 9 Actuators figure 3 10 Display figure 3 11 Keyboard figure 3 12 Reset Data figure 3 13 IHSERTER Display Keyboard Reset Data figure 3 5 The INSERTER service menu 32 1 The menu SENSORS This menu see figure 3 6 consists of the following menus Photocell condition figure 3 7 e Digital inputs figure 3 8 SENSORS Photocell condition Digital inputs figure 3 6 The menu SENSORS Photocell condition In the FPI 5000 I and FPI 5000 C so called intelligent photocells are used This implies that within a certain control range the currents of the photocell transmitters are adjusted in such a way that the no paper output voltage of the photocell receiver falls within a certain voltage range of the photocell receiver In this way fair amounts of dust present on the photocell sensors are compensated for The control mechanism ensures that very reliable paper no paper decisions are being made based on t
130. outer nut 1 securing the inner nut 2 Turn the inner nut to adjust the correct distance Replace the outer nut and check the adjustment Note An increased variation of the envelope stop position can be caused by excessive play in the lower gear train A slight reduction in the distance decreasing the pressure spring length may give the required result 10 9 Flapscraper 510 02 78 rev 01 0 01 2002 service manual FPI 5000 I Remove the base cover as described n paragraph 1 9 Base cover figure 10 9 Refer to figure 10 9 The flapscraper 3 must be positioned so that its lower edge is aligned with the lower edge of the envelope guide l To adjust Slacken the two hex head screws 2 securing the flapscraper 3 on both sides Move the flapscraper to adjust the correct position Retighten the two hex head screws and check the adjustment Note Depending on the envelope type and flap shape a different setting may be necessary 10 10 Lower insert rollers transportation table rev 01 0 01 2002 510 02 79 service manual FPI 5000 I To ensure correct document transport carry out the following check Raise the loc to the vertical position as described in paragraph 1 1 Loc insert table straight edge transportation table lower insert roller figure 10 10 Refer to figure 10 10 A suitable straight edge positioned as indicated must contact all three points as shown If this condition does not exist the
131. p 14 Pull the sprocket 13 from the axle Take care of the key 12 Slide the drive pulley 11 off the axle Take care not to loose the pin 8 Belt tensioner pulley Removal Refer to figure 3 1 Remove the two hex head screws 10 with washers 9 securing the belt tensioner 29 Shift the belt tensioner assembly in the front side direction and withdraw it when possible Slide the pulley 16 off the belt tensioner Take care of the washer 30 Adjustment See paragraph 10 3 Main drive belt 510 02 18 rev 01 0 01 2002 service manual FPI 5000 I d BA 7 O gt Q JA 9 AX S Y RAY 4 KL 0 4 gt 7 SS on M f Q 2 SS don PR ae m Y 37 36 353433 figure 3 2 rev 01 0 01 2002 510 02 19 service manual FPI 5000 I 3 5 Sprockets 3 5 1 Sprockets short chain Remove the short chain as described n paragraph 3 1 1 Short chain Sprocket 15T item 27 Removal Refer to figure 3 2 Slide the sprocket 27 off the belt tensioner 28 Take care of the washer 29 Sprocket 22T item 25 Removal Refer to figure 3 2 Remove the spring clip 26 Pull the sprocket 25 from the axle Take care of the key 24 Sprocket 15T item 31 Removal Refer to figure 3 2 Remove the spring clip 30 Pull the sprocket 31 from the axle Take care of the key 32 3 5 2 S
132. page 510 01 6 an upstream to a downstream direction Assuming that the trailing envelope edge has passed the rollers 27 and 30 this s now the leading edge of the envelope being transported through the sealing rollers After passing the sealing rollers the envelope is exited to the rear exit The exit detector PH4 monitors the passing envelope Note Both the clutched envelope transport section 2 1 and the main transport sections 2 2 and 2 3 can be manually performed After lifting the side cover there is access to a hand knob By rotating this knob clockwise the envelope transport is activated By both pressing this knob and clockwise rotating it the main transport is activated This knob not only is meant for operational purposes but for service purposes as well Refer to the service test in section 3 2 of the electrical description The motor is inactive in this case for the opened side cover causes microswitch MS to interrupt the motor relay drive current 510 01 8 rev 01 0 01 2002 service manual FPI 5000 I 1 Overview The FPI 5000 I inserter performs the following tasks Transport an empty envelope from the hopper to the insert position 2 Transport a single document or document set from the FPI 5000 C to and in the opened envelope 3 Eject and seal the filled envelope and transport it to the rear exit or side exit The simplest diagram of this process consists of just three arrows These three tasks make up just on
133. portation axle Transportation axle Part code FPI 5000 I Ouantity Remarks number FPI 5000 I 83 18 82 26 04 18 43 28 08 23 47 36 05 04 14 04 11 84 73 34 73 04 09 48 43 05 35 03 11 07 02 11 25 83 29 91 04 09 51 73 22 94 08 28 01 76 04 66 04 08 37 75 37 51 05 23 48 24 69 52 05 24 83 04 69 5 03 11 81 05 24 57 45 19 02 04 10 94 04 23 21 43 26 20 43 26 12 N A Ke gt N e e rev 02 0 02 2002 service manual FPI 5000 I rev 02 0 02 2002 510 04 11 service manual FPI 5000 I 40 39 38 11 12 13 14 15 28 27 26 25 24 23 1 2 3 4 5 6 7 8 9 10 33 32 31 30 2 Figure 3 510 04 12 rev 02 0 02 2002 service manual FPI 5000 I Figure 510 04 12 Remarks illustration Description Part code Quantity Remarks code number number FPI 5000 I Support 23 47 36 1 2 Setscrew x 8 08 28 06 2 3 Pressure adj bracket 73 53 69 4 4 Knurled ring 05 24 96 4 5 spring 03 35 51 4 6 Frame rod 43 42 45 1 7 Set screw M6 x 20 08 28 52 4 8 Tension pin 3 x 16 05 33 33 1 9 Round head screw M3 x 8 45 38 65 9 10 Bearing plate 73 55 38 1 11 Inside frame RH 95 73 07 1 12 Tension pin 2 5 x 16 05 33 22 3 13 Gearl8T 24 09 36 1 14 Spring clip 10 14 mm 05 24 83 9 15 Round head screw x 8 05 38 68 2 16 head screw x 12 05 38 82 4 17 Spacer 99x 94 1 x 2 5 mm 43 08 51 4 1
134. pper feeder of feeder unit 3 gt 5 1 FPI 5000 I error codes and warnings Error 1 1 Message Technical failure Action Call service Info Memory failure Error during the writing of zero data into FRAM formatting Press the Reset key to try again If the Stop key is pressed the formatting process 1s interrupted The machine starts with the EPROM default values Changes and counter settings are not stored Remove all papers from the machine readjustment of paper photocells Error 1 2 rev 01 0 01 2002 510 03 53 service manual FPI 5000 I Message Technical failure Action Call service Info Memory failure Error during the initialization of the FRAM Press the Reset key to try again If the Stop key is pressed the initializing process is interrupted The machine starts with the EPROM default values Changes and counter settings are not stored Remove all paper from the machine readjustment of paper photocells Error 1 3 Message Technical failure Action Call service Info No jobs available The FRAM board wasn t detected Default values will be used in stead of FRAM based values Remove all paper from the machine readjustment of paper photocells Error 1 4 Message Technical failure Action Call service Info Memory failure During the reading from or writing to FRAM PC communication errors occur Default values will be used in stead of FRAM based values Remove all paper fro
135. pplicable Whenever as solenoid is actuated the plunger is pulled into the solenoid coil To make sure that the pulling power of the solenoid coil on the plunger is maximal the plunger should not touch the bottom of the solenoid coil whenever the solenoid 1s actuated To set this requirement figure 10 5 Refer to figure 10 5 Slacken the two hex head screws 4 securing the solenoid coil 3 Push the plunger 2 together with the linkage 1 attached to it as far as it will go in the direction towards to the solenoid coil Hold the plunger into this position and then slide the solenoid coil towards the plunger until the plunger bottoms the solenoid coil Move the solenoid coil back by approximately 1 mm 0 04 inch and retighten the two hex head screws Ensure the solenoid coil and the plunger are aligned in a straight line rev 01 0 01 2002 510 02 75 service manual FPI 5000 I 10 6 Joggers Irregular feeding of certain types of envelopes can be improved by adjustment of the joggers position The joggers must be positioned equidistant from the feed roller the distance depending on the width of the envelope used To adjust Obtain a sample of narrowest envelope to be used AO fS 95 10 mm 0 4 inch figure 10 6 Refer to figure 10 6 Remove the O rings 2 from both joggers 1 and 5 Slacken the set screws of both joggers Position the middle of the envelope on the feed roller 3 and adjust
136. pring clip 17 and the washer 37 Remove the spacer 36 and the cyl pin 35 Slide the clutch off the clutch shaft Replacement Ensure on replacement that the stud on the bracket 24 retains the clutch 510 02 16 rev 01 0 01 2002 service manual FPI 5000 I NO 2 Las x n 2 M 247 7 N 2 U Ur 0 In Eo A WI MS UHR Hi ML The b M e ANN 4 2 A gt 9 RL Ra TV 2 Q A NR AN NM DN figure 3 1 rev 01 0 01 2002 510 02 17 service manual FPI 5000 I 3 3 Main drive belt Removal Remove the short chain as described n paragraph 3 1 1 Short chain Remove the clutch as described in the previous paragraph Refer to figure 3 1 Slacken the two hex head screws 10 and release the belt tensioner 29 Remove the drive belt 33 from the pulleys 11 16 and the motor pulley 32 Adjustment See paragraph 10 3 Main drive belt 3 4 Pulleys Motor pulley Removal Remove the main drive belt as described in the previous paragraph Refer to figure 3 1 Slacken the set screw 31 and slide the motor pulley 32 off the motor axle Replacement Ensure on replacement that the set screw rests on the flattened part of the motor axle Main drive pulley Removal Remove the main drive belt as described in the previous paragraph Refer to figure 3 1 Remove the spring cli
137. prockets long chain Remove the long chain as described in paragraph 3 1 2 Long chain Sprocket 15T item 34 Removal Remove the short chain as described in paragraph 3 1 1 Short chain Refer to figure 3 2 Remove the spring clip 30 Pull the sprocket 31 from the axle Take care of the key 32 Remove the spring clip 33 Tap out the tension pin 35 Slide the sprocket 34 off the axle Take care of the spacer 36 Sprocket 15T item 38 Removal Refer to figure 3 2 Support the axle 37 and tap out the tension pin 44 510 02 20 rev 01 0 01 2002 service manual FPI 5000 I Slide the gear 45 off the axle Support the axle 37 and tap out the tension pin 39 Slide the sprocket 38 off the axle Sprocket 15T item 42 Removal Refer to figure 3 2 Support the axle 1 and tap out the tension pin 41 Slide the sprocket 42 off the axle Sprocket 15T item 46 Removal Remove the clutch as described in paragraph 3 2 Clutch Refer to figure 3 2 Slide the sprocket 46 off the clutch shaft Take care of the washer 43 Sprocket 15T item 47 Removal Remove the main drive pulley as described in paragraph 3 4 Pulleys Refer to figure 3 2 Remove the spring clip 49 and the washer 48 Slide the sprocket 47 off the bearing pin Take care of the spacer 40 Sprocket 15T item 19 Removal Refer to figure 3 2 Support the axle 2 and tap out the tension pin 18 Slide the sprocket 19 off the axle Take care of the washe
138. pulley 5 and slide the pulley off the drive axle 6 2 3 Gears Remove the front and rear drive axle assembly as described in paragraph 6 2 1 Main drive belt Gear 15T item 19 Removal Refer to figure 6 2 Tap out the tension pin 15 and slide the gear 19 off the drive axle 21 Gear 18T item 11 Removal Refer to figure 6 2 Push the gear 11 of the tension pin 10 Tap out the tension pin Slide the gear 11 off the drive axle 7 Take care of the bearing 12 the washer 13 and the bushing 9 6 3 Document inserting Remove the loc cover as described in paragraph 6 1 Covers and plates Open the loc as described in paragraph 1 1 Loc 6 3 1 Rollers Set of transportation rollers 36 mm Removal Refer to figure 6 3 Remove the round head screws 13 the washers 12 and the guides 11 from both sides of the axle 8 Remove the pressure springs 17 and 19 Slacken the set screw of the roller 22 and slide it off the axle 18 Remove the spacer 21 and the bearing 20 Withdraw the axle in the right hand side direction Take care of the bearing 16 and the spacer 15 Slacken the set screw of the roller 14 and slide it off the axle Replacement Ensure on replacement that the set screws rest in the grooves of the axle The rollers must have an axial play of approx 1 mm 0 04 inch to ensure independent movement of the right and left hand roller 510 02 48 rev 01 0 01 2002 service manual FPI 5000 I R KE Pd
139. r 3 Sprocket 15T item 14 Removal Refer to figure 3 2 Remove the countersunk screw 17 securing the pulse disc 15 Remove the pulse disc together with the two spacers 16 Take care of the pulse disc detector 8 Support the axle 7 and tap out the tension pin 13 Slide the sprocket 14 off the axle Take care of the washer 5 and the spacer 6 rev 01 0 01 2002 510 02 21 service manual Sprocket 18 item 12 Removal Refer to figure 3 2 Tap out the tension pin 11 Slide the sprocket 12 off the axle Take care of the washer 10 and the spacer 9 Sprocket 15T item 21 Removal Refer to figure 3 2 Remove the locking clip 23 and the spacer 22 Slide the sprocket 21 off the belt tensioner 4 Take care of the spacer 20 3 6 Gears Gear 18T item 39 Removal Refer to figure 3 3 Remove the clamping ring 38 Slide the gear 39 off the axle Gear 15T item 31 Removal Refer to figure 3 3 Remove the clamping ring 33 and the washer 32 Slide the gear 31 off the axle Take care of the washer 30 Gear 15T item 45 Removal Refer to figure 3 2 Support the axle 37 and tap out the tension pin 44 Slide the gear 45 off the axle 510 02 22 FPI 5000 I rev 01 0 01 2002 COOC TO 0 IO 91 CW IS ANSI 42 41 40 39 38 37 36 35 34 23 22 2 ENUCU 9014195 OOSNI VS service manual Gear 28T item 36 Removal Refer to figure 3 3 Remove the clamping ring 34 and
140. r 3 73 Message Technical failure Action Call service Info Collator sensor defective The photocell transmitter LED of photocell VPH2 1s defective Check the wiring Error 3 74 Message Collator sensor dusty Action Clean sensor Info none Sensor needs readjustment after removed dust causes a too high LED current setting of the relevant photodiode rev 01 0 01 2002 510 03 71 service manual FPI 5000 I Error 3 75 Message Collator sensor dusty Action Clean sensor Info none The relevant photocell collator area input photocell VPH2 s dusty to such an extent that at least 80 of the photodiode current has been reached Compared with error 3 71 there s still a certain dust margin Readjust the photocell after clean ng with no paper present Error 3 80 Message Technical failure Action Call service Info Divert motor failure The divert motor VM2 is checked via its accompanying pulse disk and slotted photocell VSPHS5 Provided VSPHS is correctly operating see the service software this motor is probably defective Error 3 81 Message Technical failure Action Call service Info No Divert option This error is generated during system initialisation if the FRAM data supposes the divert unit to be present but it appears to be intentionally or accidentally removed Error 3 90 Message Technical failure Action Call service Info Update Reader SW The Eprom on the reading board d
141. r boss 28 19T Axle Pressure spring 1 5 mm Spring holder disc Washer 17 x 8 4 x 1 6 mm Nut M8 Bracket assy Led including holder without lens Pan head tapping screw Hex head screw MA x 8 Frame rod Frame rod Part code FPI 5000 I Quantity Remarks number FPI 5000 I 95 71 27 24 09 58 04 10 94 04 08 28 95 71 33 24 63 11 43 25 87 43 25 86 03 11 73 24 69 43 45 37 38 45 19 06 13 33 31 04 24 41 45 38 55 45 38 80 43 29 43 43 29 45 Re N e mm Se W N e W rev 02 0 02 2002 service manual FPI 5000 I rev 02 0 02 2002 510 04 37 FPI 5000 I service manua 50 51 52 N M Cc 28 29 30 31 12 1 10 23 22 21 20 19 18 17 16 15 14 13 21 26 25 24 Figure 10 rev 02 0 02 2002 510 04 38 service manual FPI 5000 I Figure 510 04 38 Remarks illustration Description Part code Quantity Remarks code number number FPI 5000 I Cover assy 98 00 01 1 2 Knob white 97 00 41 8 3 Spacer O8 x O4 3 x 15 mm 98 00 30 4 4 Spacer O8 x 04 3 x 7 5 mm 04 07 78 2 5 Round head screw M4 x 20 45 43 17 1 6 Lock washer 5 32 05 24 31 1 7 Fuse 3A slow blow 12 11 12 3 8 Eprom 98 02 11 1 9 Mainboard 94 80 01 1 10 Cover plate 36 04 49 1 11 Countersunk head screw x 16 05 38 77 2 12 Guide bracket 36 07 14 2 13 Hex head screw M4 x 8 05 38 80 7 14 Transformer 12 12 74 1 15 Capacitor 4 mF 220 V 12 12 79 1 C
142. r cover 7 Remove the two round head screws 19 and withdraw the gear cover 18 Refer to figure 4 2 Remove the spring clip 2 securing the gear 1 Remove the spring clip 20 the washer 19 and the bearing 16 Slide the axle in the left hand side direction and remove the spacer 13 and the gear 11 Take care of the slip clutch 10 and the cyl pin 7 Gear 28T item 1 Removal Remove the first set of transportation rollers 36 mm as described in the previous paragraph Refer to figure 4 2 Slide the gear 1 off the axle 3 Gear 35T item 12 Removal Refer to figure 4 2 Remove the clamping ring 8 and the washer 9 Slide the gear 12 off the bearing pin Take care of the two spacers 14 and 15 rev 01 0 01 2002 510 02 35 service manual FPI 5000 I Gear 28T item 25 and gear 19T item 26 Removal Remove the gear 35T item 12 as described previously Refer to figure 4 2 Push the left hand transportation roller 6 inwards from the cyl pin 5 Remove the cyl p n from the clutch shaft 33 Push the right hand transportation roller 31 inwards from the cyl pin 32 Remove the cyl pin from the clutch shaft Remove the spring clip 30 Remove the spring clip 23 the spacer 22 and the washer 21 Slide the clutch shaft in the left hand side direction Take care of the washer 17 Remove the freewheel clutch assembly 24 25 26 and 27 Take care of the spacer 28 and the washer 29 Remove the three countersunk screws 24 and slide
143. re 4 3 Slacken the set screw of the left hand metal roller 30 Slide the left hand metal roller off the axle 18 Push the left hand transportation roller 28 inwards from the cyl pin 29 Remove the cyl from the axle Slide the left hand transportation roller off the axle Pull the air hose from the transmitter 32 Cut the wire strap securing the wiring to the bracket 31 Remove the two hex head screws 6 and withdraw the bracket Take care of the wiring Remove the spring clip 13 and the washer 12 Slide the axle in the left hand side direction push the bearing 21 from the frame plate 33 and carefully withdraw the axle from the machine Take care of the bearing 16 Remove the spring clip 19 the two washers 22 and the bearing 21 Push the right hand transportation roller 20 outwards from the cyl pin Remove the cyl pin from the axle Slide the right hand transportation roller off the axle Fourth set of transportation rollers 31 7 mm Remove the long chain as described in paragraph 3 1 2 Long chain Removal Refer to figure 3 1 Disconnect the clutch 34 Refer to figure 4 3 Remove the two round head screws 14 securing the ball bearing 15 Slacken the set screws of the two transportation rollers 23 on the clutch shaft 24 Remove the spring clip 25 Carefully withdraw the clutch shaft in the right hand side direction out of the machine and slide the two transportation rollers off it Take care of the bearing 27 and
144. re parameters Therefore it is important to clear the machine of paper in this situation in order to establish correct photocell parameters Key IHSER TER 2 Remove envelopes 3 from inserter 4 Reset Data 5 6 figure 3 13 The menu Reset Data 3 3 The VERTICAL SYSTEM menu The VERTICAL SYSTEM menu of figure 3 14 covers the non inserter part of the total system It consists of the following three menus Folder settings figure 3 15 System settings figure 3 16 Service tests e Default collator stop figure 3 23 rev 01 0 01 2002 510 03 37 service manual FPI 5000 I figure 3 14 The menu VERTICAL SYSTEM 3 3 1 The FOLDER OFFSET menu In the FPI 5000 C the folding process is implemented by the timing of two cam discs one for each folding position rather than by the use of mechanical folding stops The timing is determined by the document length of the sheets to be folded Given these tolerances in the activation times of the clutches involved the service software provides for an equivalent shift in the folding positions thus compensating a clutch activation time that deviates from the average value In the FOLDER OFFSET menu of figure 3 15 you first select the folder Than you can set the equivalent shift in the folding position between 20 mm and 20 mm By processing test material you can decide if subsequent corrections in these settings are necessary Key FOLDER OFFSET 2 Folder 1 3 Folder 3
145. rent voltage paper status PH2 Flapcel 010 0 91 0 OK PH4 Exitcel 024 41V OF PH3 Loccel 016 1 0 1 1 Env track 016 1 0 0 O U AK U NM Press Llear gt to reset photocells figure 3 7 The screen for the IN PHOTO CONDITION IN DIGITAL INPUTS The IN DIGITAL INPUTS menu of figure 3 8 shows the real time status of the digital photocell that monitors the FPI 5000 I pulse disc This photocell sees either a cog or an indented area of the pulse disc There is a fifty fifty chance of a digital photocell seeing a cog or an indented area So by one or more times manually moving a pulse disc or any mechanical item to which the pulse disc is covered the status should change from Open into Covered or in the reverse direction In a future service software release a test routine will be built in to dynamically test the pulse discs The indented areas of the pulse discs should be free of any production residue which is thoroughly checked for in the factory or dust particles which may occur during operational use In this menu the FPI 5000 I and FPI 5000 C covers are tested as well The status of the loc cover and the status of the front cover of the FPI 5000 I are shown separately Extern relates to both the folder cover and the vertical transport cover of the FPI 5000 C If at least one of those covers is open the status of Extern is open as well rev 01 0 01 2002 510 03 33 service manual FPI 5000 I IH
146. ressed The eject rollers and closer solenoids will be activated and after a short time deactivated during one period of test key pressing During normal operational use these actuators are always activated during a short time This test reflects this situation If the fingers actuator 1s selected the fingers move forward as soon as the test key 15 pressed Only after releasing the test key the fingers will move back to their rest position Testing the envelope track will result in switching on the motor and activating the envelope track clutch Key ACTUATORS 1 M Sol 2 Selert 3 So4 Env track 4 5 figure 3 10 The menu ACTUATORS 3 2 4 menu DISPLAY In this menu see figure 3 11 you can toggle between a normal display and a diapositive inverse LCD display In addition to this you can check whether all the display pixels are still correctly operating You can observe this if you keep the toggling screen key pressed After you release this key the screen display will toggle from normal to diapositive or from diapositive to normal So for a complete display test you need two key press cycles Key DISPLAY Toggle screen O U figure 3 11 The menu DISPLAY rev 01 0 01 2002 510 03 35 service manual FPI 5000 I 3 2 5 The menu KEYBOARD In this screen see figure 3 12 the correct functioning of each of the ten keys six soft keys and four general keys can
147. ring a startup with FRAM reading errors or during the photocell test This is most likely caused by paper being present under the photocell Error 1 54 Message Technical failure Action Call service Info Loc sensor defective The no paper output voltage of photocell PH3 cannot be set on a value between 0 7 V and 1 3 V This message may occur during the photocell adjustment at the very first start of the machine or during startup with FRAM reading errors or during the photocell test This is most likely caused by paper being present under the photocell Error 1 55 Message Technical failure Action Call service Info Exit sensor defective The no paper output voltage of photocell PH4 cannot be set on a value between 0 7 V and 1 3 V This message may occur during the photocell adjustment at the very first start of the machine or during startup with FRAM reading errors or during the photocell test This is most likely caused by paper being present under the photocell Error 1 56 Message Technical failure Action Call service Info Track sensor defective During the start of the machine no photo diode current of photocell PHI is detected The photodiode is not properly connected or not connected at all This error only may occur after the field replacement of the photocell or after any service activities involving replacing circuit board connections Error 1 57 Message Technical failure 510 03 60 rev 01 0 01 200
148. ring clip 10 14 mm 05 24 83 3 24 Mounting plate 95 72 04 1 25 Gear 28T 24 11 40 1 26 Refer to item 11 27 Tension pin 2 5 x 18 05 33 23 1 28 Drive axle 43 26 41 1 29 Inside frame RH 95 73 07 1 30 Locking block 04 11 77 1 3 Round head screw M3 x 8 45 38 65 3 32 Transportation roller 30 mm 04 18 27 2 33 Cyl pin 2 5 x 16 05 23 46 2 34 Axle for pulse disc 23 59 52 1 35 Guide plate 23 22 93 1 36 Round head screw x 8 05 38 65 2 37 Countersunk head screw x 10 05 38 74 2 38 Fibre washer 17 x 10 2 x 0 5 mm 04 01 29 2 39 Mounting pin 43 61 75 2 40 Magnetic clip 95 70 91 1 4 Holder 98 00 20 1 42 Hex head screw x 8 05 38 80 2 43 Spacer 15 x 10 4 x 3 mm 04 08 58 2 44 Round head screw x 16 05 38 71 10 45 Inside frame LH 95 73 09 1 02 0 02 2002 510 04 25 Figure 510 04 24 Remarks illustration code number 46 47 510 04 26 service manual Description Refer to item 11 Refer to item 11 FPI 5000 I Part code Quantity Remarks number FPI 5000 I rev 02 0 02 2002 service manual FPI 5000 I rev 02 0 02 2002 510 04 27 service manual FPI 5000 I 13 14 15 16 17 SS 7 SO r n SER j Q NGS 9 Y y 5 6 7 8 9 101 12 3 2 SSS 1 zZ N 41 40 39 38 37 36 35 34
149. rt is considered finished if and when document detector PH3 detects the trailing edge of the document set Then a number of actions take place a clutch RPMI is activated to release the flap b solenoid So2 is shortly activated resulting in the ejection roller in the loc moving down By spring action after switching S02 off this driven roller is pulled high again Now the envelope is rejected from the insert table S02 1s deactivated after the complete passage of the filled envelope Also by activating a new envelope 15 transported to the insert table The filled envelope passes the lowered brushes The envelope passes the second eject rollers and the sealing track rollers On a certain time the leading envelope edge triggers flag switch FS1 Now a pulse count is started The envelope passes the sealing transport roller lower sealing roller combination rollers 27 and 30 Flag switch FS is restored to its rest position after the trailing envelope edge has passed The upper reverse roller is held high i e this roller doesn t contact the lower reverse roller by a spring After a time determined by the FS1 triggered pulse count So4 1s activated The envelope is between the upper and lower reverse rollers By the So4 action the upper reverse roller now is temporarily lowered Given the turning direction of the lower reverse roller 28 which also transmits mechanical drive to the loc the transport direction of the envelope is ab
150. rtup initial DFC settings are made Go to test 3 DFC of the first level service tests See section 4 1 3 The display must show a value of between 250 and 750 millivolts This is the rest value offset for a thickness of zero After all the feeler has been removed The sensitivity amounts to 1 V mm 1000 mV mm For example a thickness of 1 mm corresponds with a 1000 mV higher output voltage SO gt V DH Note This mechanical adjustment ensures that of the total 5 mm range of the the first 1 mm is not used This results in the linear behaviour of the 1 V per millimeter conversion Jumpers on the display keyboard 95 70 72 5 _ _ 5 OFF White Black screen 222 ON jBlack white screen 510 03 28 rev 01 0 01 2002 service manual FPI 5000 I 3 Service software Note The service software as discussed here includes the service software for the feeder folder unit FPI 5000 C as well The FPI 5000 C has no user interface of its own Specific items of the FPI 5000 C electrical description are discussed in document 520 03 related service software is discussed in document 520 10 OMR appendix FPI 5000 C 3 1 General The main screen of the service menu is accessed after pressing key 4 in the second part of the main menu of figure 3 2 Enter the pin code 4351 in the job access menu of figure 3 3 You will now enter the main service menu screen of figure 3 4 The service so
151. ruptly changed from see foldout on page 510 01 6 an upstream to a downstream direction Assuming that the trailing envelope edge has passed the rollers 27 and 30 this s now the leading edge of the envelope being transported through the sealing rollers After passing the sealing rollers the envelope is exited to the rear exit The exit detector PH4 monitors the passing envelope Note Both the clutched envelope transport section 2 1 and the main transport sections 2 2 and 2 3 can be manually performed After lifting the side cover there is access to a hand knob By rotating this knob clockwise the envelope transport is activated By both pressing this knob and clockwise rotating it the main transport is activated This knob not only is meant for operational purposes but for service purposes as well Refer to the service test in section 3 2 of the electrical description The motor is inactive in this case for the opened side cover causes microswitch MS to interrupt the motor relay drive current 510 01 8 rev 01 0 01 2002 service manual FPI 5000 I Mechanical rev 01 0 01 2002 510 02 1 service manual FPI 5000 I 510 02 2 rev 01 0 01 2002 rev 01 0 01 2002 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 1 14 2 1 22 2 3 3 1 3 1 1 3 1 2 32 3 3 3 4 3 5 3 5 1 3 2 2 3 6 3 7 4 1 4 1 1 4 1 2 4 1 3 service manual Contents Section Covers and plates Loc Water ta
152. s Software versions figure 3 25 510 03 44 rev 01 0 01 2002 service manual FPI 5000 I Run in figure 3 26 Localisation figure 3 27 Job settings figure 3 28 Service counters figure 3 34 SERVICE MEHU Software versions Job settings Service counters figure 3 24 The system wide SERVICE MENU 3 4 1 SOFTWARE VERSIONS The software version screen of figure 3 25 shows the software versions for the various eproms that are present in the total system If you press key 1 the internal revision levels are shown as well Key SOFTWARE VERSIONS Main board inserter 980211 Main board VS 3275012 Feeder 1 2 975013 Feeder 3 4 975013 Feeder 5 275013 _2 level 3 O U AK U figure 3 25 The SOFTWARE VERSION screen 342 TEST The run in test screen of figure 3 26 shows a counter of which the default value is 6000 This is the number of process cycles that will be emulated with no paper whatsoever present in the machine rev 01 0 01 2002 510 03 45 service manual FPI 5000 I After pressing the green Start key the run 1 test will start Pressing the red Stop key will result in stopping the run n test After each process cycle the counter 15 decremented Once the counter value is below 6000 you can restore the 6000 situation by pressing key 6 The machine stops automatically if the counter value is zero If you have some covers removed but not the
153. s the collator area must accommodate for the longest possible document size of 14 inch t makes sense to make arrangements for a paper stop for shorter documents in order to obtain a higher process speed PAPER STOP Select job Paper stop Save and exit figure 3 30 The PAPER STOP menu The DOCUMENT OFFSET menu The vertical transport of documents fed by the various feeders 1s arranged in such a way that the documents are partially overlapping each other This overlapping scheme ensures that the documents are properly aligned in the collator area In the document offset menu of figure 3 31 you can set the extend to which the documents are not overlapping each other 1 e the document offset value The default value is 50 mm The document offset can be varied between 20 mm and 75 mm 510 03 48 rev 01 0 01 2002 service manual FPI 5000 I DOCUMENT OFFSET Document offset Save and exit figure 3 31 The DOCUMENT OFFSET menu The SECURE JOB menu With the SECURE JOB menu of figure 3 32 the selected job can be secured i e locked This job can not be deleted and can not be changed in the job menu either However a locked job still can be copied into another job that can be modified SECURE JOB figure 3 32 The SECURE JOB menu The BRE offset menu If a document is longer than the set address fold but shorter than the envelope height this document sometimes will be unnecessarily folded Under
154. safety covers you can observe the various sequences of mechanical actions which reflect the sequence of events during normal operational use of the machine Note 1 It is strongly recommended to perform the run in test directly after you have powered up the machine and entered the service software Also it is advised to switch the machine off and on again after finishing the run in test Note 2 It is also strongly recommended to perform the run in test without any documents present in the machine The timing of the actions for a simulated process cycle are fixed so they are not based on parameters such as the document length run in test with documents present in the machine would only result in severe paper jamming Key RUH IH TEST Counter O U U M figure 3 26 The RUN IN TEST screen 3 4 1 LOCALISATION The localisation menu of figure 3 27 shows two options You can select the language for the operational menus Currently the options are English Dutch German Spanish Italian French and Katakana As to the document standard options you have a choice between none and ISO In the ISO case predefined document formats are used in the relevant menus such as A4 A5 4 inch 6 inch 7 inch 8 inch 11 inch 12 inch and 14 inch Key LOCALISATION Document standard 4 Save and exit figure 3 27 The LOCALISATION menu 3 4 4 JOB SETTINGS 510 03 46 rev 01 0 01 2002 service manual
155. should be placed direct underneath the BRE in the set The whole BRE offset is based on friction between documents within a set Therefore it is necessary to make use of these conditions to reduce the risk of bad transporting folding and inserting BRE OFFSET figure 3 33 The BRE offset menu 3 4 5 The SERVICE COUNTERS menu This menu screen see figure 3 33 contains three numerical counter items All these three items are related to process cycles and can be set by the service engineer counter Since last visit This number of process cycles can be reset to zero by the service engineer during the last servicing action During the start of the machine the value of this counter is compared with the value of Next visit after If the latter value 15 exceeded error message 1 35 will appear The error screen is shown in figure 3 36 e The counter Since installation This value can be changed in the menu screen of figure 3 35 You enter this screen by simultaneously pressing keys 1 and 3 in the menu screen of figure 3 34 counter Next visit after This value can be set by the service engineer in increment or decrements of 10 000 The maximum value 1s 6 000 000 510 03 50 rev 01 0 01 2002 service manual FPI 5000 I figure 3 34 The SERVICE COUNTERS menu Key SERVICE COUNTERS 1 2 3 il Installation nn 5 Save and exit figure 3 35 The menu for readjusting the service counter Since
156. st is removed In both cases it 1s advised to readjust the photocells Normally the photocell current percentage lies between 10 and 50 This results in the message ok A percentage between 50 and 80 indicates the presence of dust and in an accompanying dust message If the photocell current percentage is higher than 80 an error message will be issued The only way to leave this menu is to press on the Escape key figure 3 18 The two screens for the FV PHOTO CONDITION 510 03 40 rev 01 0 01 2002 service manual FPI 5000 I FU DIGITAL INPUTS 1 Status Fi DIGITAL INPUTS 2 Status Cam folder open Test folderi Pulse disc Central 0 Pulse disc Collator 0 Cam folder Test folder Test both Pulse _disc Divert 1 MaxiFeeder Switch The menu FV DIGITAL INPUTS The two digital inputs screens of figure 3 19 are showing the real time status of the digital photocells that monitor the pulse discs and cam discs Such a photocell sees either a cog or an indented area of the pulse disc or either a cam disk or no cam disk There is a fifty fifty chance of a digital photocell seeing a cog or an indented area So by one or more times manually moving a pulse disc or any mechanical item to which the pulse disc is covered the status should change from Open into Covered or in the reverse direction The status of the two folder cam discs can be tested by pressing the key Test folder 1 or Test folder 2
157. switch Flag switch Pulse disc detector Document thickness detector Envelope and document detectors Envelope detector Flap detector Exit detector Document detector FPI 5000 I 31 31 35 39 40 40 42 44 45 45 46 46 47 48 48 48 50 53 54 54 56 57 57 59 60 60 60 62 62 62 63 64 65 66 67 67 68 69 70 rev 01 0 01 2002 rev 01 0 01 2002 10 10 1 10 2 10 3 10 4 10 5 10 6 10 7 10 8 10 9 10 10 10 11 service manual Adjustments Short chain Long chain Main drive belt Microswitches Solenoids Joggers Separation roller Friction brake Flapscraper Lower insert rollers transportation table Upper insert rollers loc FPI 5000 I 71 71 72 73 74 75 76 TI 18 79 80 81 510 02 5 service manual FPI 5000 I 510 02 6 rev 01 0 01 2002 service manual FPI 5000 I General instructions Disconnect the mains supply before performing any maintenance Warning The covers and microswitches are fitted by your protection Do not operate the machine with any cover removed and with a microswitch cheated or a hazard to health will exist Throughout this manual the terms left and right hand side and front and rear side of the machine are used These are made with the machine viewed from the input document feed side of the machine The replacement procedures are the reversal of the removal procedures rev 01 0 01 2002 510 02 7 service ma
158. t voltage 100 nF capacitors and ferrite beads extensively locally decouple all supply lines 510 03 8 rev 01 0 01 2002 service manual FPI 5000 I Combined display key circuit board The communication between the micro controller on the main board and the combined display key circuit board 95 70 72 see figure 1 14 figure 1 15 and figure 1 16 is based on the simulated I C bus signals SCL SIM and SDA SIM the databus signals ADO through AD7 the read write signals NRD and NWR and the control signals DIS 1 DIS 2 and DIS 3 The connections with the control panel board are made via J372 on the main board The combined display key circuit board is also powered via the main board VCC and GND Locally a 15 V power supply voltage and a high frequency AC voltage for the LCD backplane are generated Main board photocells The photocells PH1 through PH4 each consist of an infrared photodiode as transmitter TX and a phototransistor as receiver RX The output voltage of the accompanying Digital to Analogue Converter DAC controls the current through each photodiode This DAC is the U230 chip in figure 1 5 The amplified voltage monitors the total current of the four photodiodes across the resistors R214 and R215 The CPU provides the DAC inputs via the local simulated SCL SIM and SDA SIM PC bus The CPU bases the DAC voltage on the relevant input voltage on a ADC channel which is derived from the phototransistor output voltage with no pap
159. tensioner Drive axle Motor 220 240V 50Hz Motor 100 115V 60 Hz Transportation axle 05 33 21 73 26 48 05 33 22 04 23 13 04 08 37 24 11 40 24 09 36 05 24 55 04 01 43 04 08 58 05 24 81 03 11 88 04 24 26 73 26 56 82 16 22 45 37 30 05 38 65 23 59 52 45 38 65 45 19 02 95 73 03 05 26 02 43 26 16 13 29 32 45 38 80 13 38 84 95 72 03 05 24 83 05 38 69 45 37 58 04 20 03 04 08 49 73 54 31 24 08 43 24 08 57 43 25 89 04 18 37 04 14 64 05 38 68 12 10 52 73 34 76 04 18 35 12 09 98 12 10 46 43 28 84 S LL V 4 W A SS SS on o m O N N DA 510 04 29 Figure 510 04 28 Remarks 510 04 30 illustration code number 45 46 47 48 49 50 51 22 53 54 25 56 37 58 59 60 61 62 63 64 65 66 67 service manual Description Grommet Transportation axle Transportation axle Screen plate Clamping ring 3 mm Tension spring Lever Draw bar Hex head screw M4 x 12 Self locking clip Solenoid Washer 12 x 4 3 x 1 mm Hex head screw M4 x 8 Rubber roller 28 mm Drive axle including handle assy Locking plate Tension pin 2 5 x 20 Pulley axle assy Bearing pin Lever microswitch Insulating plate Microswitch Round head screw M3 x 16 Part code FPI 5000 I Quantity Remarks number FPI 5000 I 12 11 64 43 26 18 43 26 20 43 34 49 05 24 63 03 35 04
160. ternal 24 V 24V 2 Replace fuse after inspecting the electronics for possible causes rev 01 0 01 2002 510 03 57 service manual FPI 5000 I Error 1 33 Message Technical failure Action Call service Info Fuse 3 and 4 blown Fuses 3 and 4 defective No external 24V 1 and 24V 2 Replace fuses after inspecting the electronics for possible causes Error 1 34 Message Technical failure Action Call service Info Communication failure The upstream system connector between the FPI 5000 I and the FPI 5000 C base unit is not connected Error 1 35 Message Preventive maintenance Action Call service Info none This message appears during the start of the machine if the value of counter since last visit exceeds the value of the counter Next visit after See section 3 4 5 in chapter 3 for details Error 1 36 Message Document stoppage Action Remove documents Info Transport failure The DFC unit cannot be adjusted correctly Possible causes DFC unit not electrically connected DFC unit pushed in too far a mechanical DFC setting issue assuming no paper is present between the DFC sensors DFC unit defective Error 1 37 Message Technical failure Action Call service Info Main motor failure The pulse disc photocell of PD1 doesn t deliver any pulses at all or too few pulses Apart from a defective PD1 this error message is issued if the motor is mechanically overloaded or blocked It may help to
161. the FPI 5000 C board 97 50 10 The divert pulse disc is mounted on the divert motor VM2 Its movement is monitored by the slotted photocell VSPHS The state of VSPHS is reflected by LED D304 on the 5000 C board 97 50 10 The cam disc of folder 1 1s mounted on an axle that is driven by the fold table 1 clutch VCL3 Its movement is monitored by the slotted photocell VSPH2 The state of VSPH2 is reflected by LED D301 on the FPI 5000 C board 97 50 10 The cam disc of folder 2 is mounted on an axle that is driven by the fold table 2 clutch VCL4 Its movement is monitored by the slotted photocell VSPH3 The state of VSPH3 is reflected by LED D302 on the FPI 5000 C board 97 50 10 figure 3 19 The two screens for the FV DIGITAL INPUTS The menu FV ACTUATOR TESTS The FPI 5000 C has eight actuators plus two additional actuators 1 e clutches for each added feeder unit The eight actuators in the FPI 5000 C base unit consist of six clutches and two DC motors With this menu see the two screens of figure 3 20 the various mechanical subsystems that are activated by these actuators can be rev 01 0 01 2002 510 03 41 service manual FPI 5000 I tested by pressing the Test key 5 see All the clutches drive mechanical subsystems that are ultimately driven by the motor in the FPI 5000 I If the vertical track option is selected the motor runs as long as the test key is pressed All mechanical items that are activated by the vertical track cl
162. the automatic mode The operator can choose the execution of a single cycle or a two stage cycle as well rev 01 0 01 2002 510 01 5 service manual FPI 5000 I 510 01 6 rev 01 0 01 2002 service manual FPI 5000 I 2 Some details The inserting and sealing process controls a number of rotating or otherwise moving items A motor provides the overall mechanical drive The machine controls the process by means of output devices called actuators This control is based on information supplied by input devices called sensors The control action itself is a program software This program also talks with the operator via a keyboard and a display The drawing on foldout page 510 01 6 shows a LH side projected overview of all the moving items sensors and actuators of the FPI 5000 I It is a summary of more detailed information discussed in the mechanical description document 510 02 2 1 Envelope transport the rollers for this process stage are engaged to the main drive by clutch RPMI During the document and insert stage these rollers are disengaged In the final ejecting sealing and exiting stage these rollers are engaged once again to release the envelope and to feed a new envelope First of all by the action of the feed and separation rollers an envelope is separated from the stack in the hopper and transported via three pairs of transport rollers The envelope detector PHI detects the leading and trailing edge of the envelope
163. the position of both joggers so that they are approximately 10 mm 0 4 inch inside of the ends of the envelope Retighten the set screws and replace the O rings Make sure that the set screws are tightened onto the flattened part of the feed axle 4 510 02 76 rev 01 0 01 2002 service manual FPI 5000 I 10 7 Separation roller Because the separation roller does not reverse a flat gradually wears on the roller surface This can be the cause of irregular feeding of the envelopes Should this occur carry out the following adjustment Remove the rear cover as described in paragraph 1 14 Rear cover figure 10 7 Refer to figure 10 7 Use the thumbwheel 1 and set the separation gap to the maximum Slacken the set screws 2 securing the separation roller Rotate the separation roller about 30 degrees in the direction indicated so that the unworn portion of the separation roller faces the feed roller 3 Retighten the two set screws Note After rotating the separation roller over 330 degrees it is necessary to replace it rev 01 0 01 2002 510 02 77 service manual FPI 5000 I 10 8 Friction brake Remove the base cover as described in paragraph 1 9 Base cover 16 mm 0 63 inch figure 10 8 Refer to figure 10 8 The friction brake is correctly adjusted when the distance between the inner faces of the two friction discs 3 i e the overall pressure spring length is 16 mm 0 63 inch To adjust Remove the
164. the processing of paper can be resumed by pressing the Start key Error 4 5 6 7 8 9 14 Message Document stoppage Action Remove documents Info Document too short During the initialisation of the machine job information loaded into the system including the document lengths for each machine If the document length for one or more specific feeders appears to be too short this error is generated Error 4 5 6 7 8 9 15 Message Incomplete set 510 03 74 rev 01 0 01 2002 service manual FPI 5000 I Action Remove documents Info Empty feeder This message occurs when two feeders are linked and used as reading stations and one of the feeders runs empty during the accumulation of a set In this case the set is assembled from two feeders The system will stop with this error message You then must reload the remainder of the set into the reading feeder as is indicated on the display After reloading press the Reset key to remove the error message Press the Start key to resume operation This message also appears if a sheet 1s not transported from the active feeder within a timeout value of two seconds In that case the system assumes that the relevant feeder during the accumulation of a set happens to be empty There are preventive measures to prevent this error Make sure that the feeders are re filled in the correct order feeder 1 first to prevent sequence errors and make sure that complete sets are loade
165. the receiver Replacement On replacement align the receiver horizontally Use the bulge on the cover plate as a reference rev 01 0 01 2002 510 02 69 service manual FPI 5000 I 9 4 4 Document detector Removal Transmitter LED Remove the loc cover as described in paragraph 6 1 Covers and plates figure 9 9 Refer to figure 9 9 Remove the pan head tapping screw 3 securing the transmitter 1 to the bracket 2 Withdraw and disconnect the transmitter Receiver Sensor Remove the base cover as described in paragraph 1 9 Base cover Refer to figure 9 9 Remove the hex head screw 4 securing the bracket 5 Carefully withdraw the bracket Take care of the wiring Remove the pan head tapping screw 7 securing the receiver 6 to the bracket Withdraw and disconnect the receiver Replacement Ensure on replacement to secure the wiring again with wire straps 510 02 70 rev 01 0 01 2002 service manual FPI 5000 I 10 Adjustments 10 1 Short chain figure 10 1 Refer to figure 10 1 The maximum movement of the chain at the indicated position is 5 10 mm 0 2 0 4 inch To adjust Remove the RH side cover described in paragraph 1 3 RH side cover Slacken the two hex head screws 2 securing the chain tensioner 1 Shift the chain tensioner to adjust the correct chain movement Hold the chain tensioner in position and retighten the two hex head screws Check the adjustment and readjust if necessary N
166. the two countersunk screws 15 securing the loc cover 14 on the front side Remove the two round head screws 13 securing the loc on the rear side Shift the loc cover in the front side direction until the rear side 1s clear from the cover plate 11 Lift the rear side of the loc cover upwards and when possible withdraw it I ON figure 6 1 rev 01 0 01 2002 510 02 45 service manual FPI 5000 I Top cover Open the loc as described in paragraph 1 1 Loc Removal Refer to figure 6 1 Slacken the four round head screws 10 with washers securing the top cover 8 on the front side Withdraw the top cover Cover plate Remove the top cover as described in the previous paragraph Removal Refer to figure 6 1 Disconnect the solenoid coil 7 Remove the round head screw 6 securing the mounting clamp 5 Take care of the crinkled washer 4 Remove the four round head screws 2 securing the brake plate 9 on both sides to the cross bar 3 Withdraw the brake plate Take care of the wiring Remove the two round head screws 1 securing the cover plate 11 to the front side of the cross bar Take care of the crinkled washer 12 on the round head screw on the right hand side Withdraw the cover plate Replacement Ensure on replacement that the cover plate 15 replaced back into the slits on both sides of the cross bar 6 2 Drive mechanism Remove the covers and plates as described in the previous paragraph 6 2 1 Main drive belt
167. the washer 35 Slide the gear 36 off the axle Take care of the washer 37 Gear 15T item 29 Removal Refer to figure 3 3 Support the axle 41 and tap out the tension pin 28 Slide the gear 29 off the axle Gear 18T item 27 Removal Refer to figure 3 3 Remove the spring clip 26 Slide the gear 27 off the axle Gear 28T item 25 Removal Refer to figure 3 3 Remove the spring clip 24 Slide the gear 25 off the axle Gear 28T item 23 Removal Remove the main drive pulley as described in paragraph 3 4 Pulleys Refer to figure 3 3 Remove the washer 21 and the locking plate 22 Slide the gear 23 off the axle Gear 18T item 10 Removal FPI 5000 I Remove the sprocket 18T item 11 as described in paragraph 3 5 2 Sprockets long chain Refer to figure 3 3 Remove the washer 12 and the spacer 11 Slide the gear 10 off the roller axle 510 02 24 rev 01 0 01 2002 service manual FPI 5000 I Gear 18T item 6 Removal Refer to figure 3 3 Remove the spring clip 7 Slide the gear 6 off the roller axle Gear 28T item 5 Removal Refer to figure 3 3 Remove the clamping ring 9 and the washer 8 Slide the gear 5 off the bearing pin Take care of the spacer 4 Gear 28T item 2 Open the loc as described in paragraph 1 1 Loc Removal Refer to figure 3 3 Remove the spring clip 3 Slide the gear 2 off the axle Gear 28T item 20 Open the loc as described in paragraph 1
168. tight rev 01 0 01 2002 510 02 73 service manual FPI 5000 I 10 4 Microswitches Loc microswitch The loc microswitch is used to detect the opening of the loc and to stop the machine as a safety precaution The microswitch is actuated via a lever by the locking rod of the loc The microswitch is working properly if it is actuated when the blue handle of the loc is pulled upwards To adjust Remove the RH side cover described in paragraph 1 3 side cover Ensure the loc is lowered and locked in the horizontal position 0 O ccc 00 cca figure 10 4 Refer to figure 10 4 Slacken the nut 4 with securing the microswitch 2 on the front side Pull the front side of the microswitch away from the inside frame as far as possible Push the microswitch towards the inside frame until the lever 1 1s actuated a click 1s heard Hold the microswitch in this position and retighten the nut Slacken the round head screw 3 securing the mounting bracket 5 to the inside frame Align the lever in the middle of the hole 6 in the RH inside frame by shifting the mounting bracket sideways and then retighten the round head screw Note Check if the rear side of the microswitch is tightened properly retighten if necessary 510 02 74 rev 01 0 01 2002 service manual FPI 5000 I 10 5 Solenoids Note The adjustment procedure of the finger solenoid is used as an example for the other solenoids the same procedure is a
169. ting the adjustment procedure The voltage should be approx 4 1 V when a single sheet 80 grams 20 Ib is under neath the sensor the voltage of a non adjusted DFC without paper is approx 5 V When this sheet is removed the voltage will drop with approx 0 25V the voltage drop depends on the thickness quality of the paper Table 3 2 gives an indication how much the voltage will drop with the relevant paper qualities rev 01 0 01 2002 510 03 43 service manual FPI 5000 I Paper quality gr Voltage drop V m table 3 2 Although the readings are correct it still could be that the DFC is not functioning correctly in AUTO mode It is recommended to clean the inner moving parts of the DFC to make sure that dust or paper particles are not affecting the DFC functioning Key FU TEST Voltage V Feeder 6 4 060 Feeder 5 4 069 Feeder 4 4 138 Feeder 3 Feeder 2 Feeder 1 KA On figure 3 22 The screen for the FV DFC TEST 3 3 4 Set default collator stop menu In this menu see figure 3 23 the default collator stop position can be set at b A4 paper size or c 14 paper size This is the start value for the collator stop position when you create a new job DEF COLL STOP 1 Select d Saue and exit figure 3 23 The menu Define collator stops 3 4 The system wide SERVICE MENU The system wide SERVICE MENU of figure 3 24 consists of the following five menu
170. to figure 5 1 Slacken the set screws of the two transportation rollers 5 Remove the spring clips 6 from both sides of the transportation axle 4 Carefully withdraw the transportation axle in the right hand side direction out of the machine and slide the two transportation rollers off it Take care that the bearings 1 with the pressure springs 2 on both sides of the transportation axle stay in place and of the washers 3 on both sides Replacement Ensure on replacement that the two transportation rollers are refitted correctly on the transportation axle narrowing part of both rollers pointing in the left hand side direction and the set screws rests into the grooves in the transportation axle rev 01 0 01 2002 510 02 41 service manual FPI 5000 I 5 2 Lower transportation rollers Remove the transportation table as described n paragraph 1 10 Transportation table Remove the front cover plate as described in paragraph 1 7 Front cover plate First set of lower transportation rollers 36 mm Removal Remove the gear as described in paragraph 3 6 Gears gear 28T item 38 Remove the long chain as described in paragraph 3 1 2 Long chain S d odi 5 gt os 9 a SL 24 7 R wo M M a 0 ui aA 7 N 39 d v i lt A 5 OS QA p amp 2 INS p CU 20 19 figure 5 2 Refer to figure 5 2 Push the two rollers 12 n the r ght hand side directi
171. touching the front of the partially completed set Only after the last document of the set has entered the collating area the complete set is aligned against the paper stop after which it is transported to the folding area Mode 2 focuses on minimal necessary paper movements high processing speed but with the potential risk of longer during paper contact between the new entering document and the partial set However this is no problem with the usual normal range of paper weights In the Mode 1 case the partial set is transported further into the Shunt area After each new document joins the partial set the new partial set is aligned against the paper stop This takes more time but the paper to paper rev 01 0 01 2002 510 03 47 service manual FPI 5000 I contact occurs over shorter distances Mode 1 focuses on operation with a wide range of paper types at some expense of the process speed MOLDE MEHU Select job Output Save and exit figure 3 29 The system output menu The PAPER STOP menu In the collator area three mechanical paper stop positions are possible one for A5 sized documents one for A4 sized documents and one for 14 inch sized documents With the paper stop menu of figure 3 30 you can assign a paper stop position to each of the currently present jobs If a job is selected during normal operational use you will get a message warning you that you have to set the mechanical stop position at the specified position A
172. transportation table in the front side direction and withdraw it Take care not to damage the rubber transportation rollers 5 in the transportation area rev 01 0 01 2002 510 02 11 service manual FPI 5000 I 1 11 Front cover Removal Remove the RH s de cover as described n paragraph 1 3 RH s de cover Remove the power supply cover as described in paragraph 1 8 Power supply cover Refer to figure 1 2 Remove the two round head screws 6 with the washers 7 Remove the four round head screws 9 securing the front cover 12 together with the two connecting plates 11 and 13 to both inside frames 10 Pull and w thdraw the two connecting plates from between the front cover and the inside frames Tilt the front cover by pulling the lower end in the front side direction and withdraw it from between both inside frames Take care of the safety cover 8 retained by the front cover Replacement Ensure on replacement of the two connecting plates that the hinge pins point outwards and that the front cover retains the safety cover 1 12 Insert table Open the loc as described in paragraph 1 1 Loc Remove the water tank as described in paragraph 1 2 Water tank Removal Refer to figure 1 1 Remove the four countersunk screws 2 securing the insert table 3 in the insert area Refer to figure 1 2 Shift the insert table in the rear side direction until the front side is clear from the outer four fingers 2 Lift the front side
173. tube plug Round head screw M3 x 8 Washer 9 x 4 3 x 0 8 mm Conductive strip Hex head screw M6 x 12 Frame rod Sleeve Conductive bearing 10 mm Washer 16 x 10 2 x 0 8 mm Spring clip 10 14 mm Rivet pin Spacer 15 x 10 4 x 5 mm Spacer 15 x 10 4 x 3 mm Tension pin 2 5 x 18 Gear 15 Gear 28T Gear cover LH Envelope feed axle Transportation axle Jogger roller assy Transportation roller 42 5 mm Feed roller 42 mm Set screw M4 x 6 Set screw M4 x 8 Flap guide Flap guide Cyl pin 2 5 x 12 Clamping ring 10 mm 04 01 41 05 24 42 45 37 53 05 24 46 23 68 69 04 10 50 24 11 67 24 08 43 05 33 22 24 08 57 04 18 37 76 04 65 08 28 01 05 23 46 43 25 89 04 18 27 46 04 56 24 13 02 45 38 65 45 37 02 04 20 03 05 38 85 43 29 44 04 09 77 04 24 26 04 01 43 05 24 83 23 17 54 04 08 37 04 08 58 05 33 23 24 09 44 24 11 40 95 71 31 95 71 28 95 71 29 04 18 75 73 25 76 73 27 31 08 28 02 08 28 06 26 03 44 26 04 78 05 23 47 05 24 81 DV BRN NOR Se eS nm A e Ne NNR Pe Ne N 510 04 35 Figure 510 04 34 Remarks 510 04 36 illustration code number 46 47 48 49 50 51 52 53 54 29 56 57 58 59 60 61 62 63 service manual Description Slipping clutch CCW 8mm Gear 35T Spacer 17 x 10 2 x 2 mm Spacer 15 x 10 4 x 7 5 mm Gear cover RH Gear 28T Gea
174. tween processing a completed set into the Eight in One subsystem and transporting an incomplete set to the shunt area If 1t appears to be an incomplete set affected by double feed errors the divert motor drives a device that pushes the incomplete set into the shunt area in such a way that the set will be hooked and thus will not be included in any subsequent multifeeding related transport of a partially completed set back into the collator area This is the Divert amp Go feature The feeder clutches FCL1 and FCL2 two for each feeder unit transport a separated sheet to its waiting position and transports it further upon request until the vertical transport mechanism takes over control Fu ACTUATOR TESTS Fu ACTUATOR TESTS T Shunt forward Feeder 6 Shunt reverse Feeder 5 Collator run in Feeder 4 Collator run out Feeder 3 Divert Feeder 2 Folder Folding table 1 Folding table 2 figure 3 20 The two menu screens for the ACTUATOR TESTS figure 3 21 The submenu for the FV ACTUATOR TESTS The menu FV DFC TEST For reasons of compactness requirements the DFC units in the feeders of the Vario Feed subsystem differ from the DFC units as used in among other inserters and feeders the FPI 5000 I The DFC screen of figure 3 22 shows the real time DFC output voltage expressed in millivolt For testing the DFC it is best to start the system with paper underneath the DFC sensor and covering the feeder photocell too This results in star
175. ulse disc is powered by the FPI 5000 I This error occurs if the FPI 5000 I and the FPI 5000 C are electrically but not mechanically coupled Error 3 58 Message Technical failure Action Call service Info Disc sensor dirty The pulses delivered by the slotted photocell VSPHI which monitors the central FPI 5000 C pulse disc show irregularities The cog no cog pattern is disturbed Excluding production residue in the room between two successive cogs the irregularities may be caused by dirt Clean the pulse disc and check the position of the slotted photocell Error 3 60 Message Document stoppage Action Remove documents Info Cover open The cover of the vertical transport area was opened during paper transport This results in a paper jam Remove the paper close the cover and press the reset key Error 3 61 Message Vert tr sensor dusty Action Clean sensor Info none The relevant photocell vertical track photocell VPHI is dusty to such an extent that the full 100 of the photodiode current has been reached Readjust the photocell after cleaning with no paper present Error 3 62 Message Technical failure Action Call service Info Vert tr sensor defect The photocell transmitter receiver combination of photocell is defective Check the wiring of both photocell parts Error 3 63 Message Technical failure Action Call service Info Vert tr sensor defect The photocell transmitter LED
176. und head screw M3 x 25 Round head screw M3 x 6 Separation spring FPI 5000 I Part code Quantity Remarks number FPI 5000 I 95 71 06 1 45 43 08 1 45 43 02 2 95 71 04 1 rev 02 0 02 2002 service manual FPI 5000 I rev 02 0 02 2002 510 04 23 Figure 6 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 21 28 29 service manual V s v 7 Cee PQ 52 2 5 4 2 39 38 37 36 2 3 5 5 6 7 8 1 510 04 24 FPI 5000 I 35 34 33 32 rev 02 0 02 2002 service manual FPI 5000 I Figure 510 04 24 Remarks illustration Description Part code Quantity Remarks code number number FPI 5000 I Frame axle 95 71 53 2 2 Cover 95 71 52 1 3 Round head screw M4 x 6 05 38 66 2 4 Countersunk head screw M4 x 10 05 38 75 2 5 Protecting plate 95 73 13 1 6 Sensor including holder 04 24 53 1 7 Countersunk head tapping screw 45 38 56 2 8 including holder 04 24 52 1 9 Front cover 95 71 07 1 10 Upper sealing roller 36 mm 73 26 48 1 11 Lower sealing roller assy 36 mm 04 23 13 1 12 Setscrew x 8 08 28 06 2 13 Transportation roller 30 mm 46 04 56 14 Transportation axle 43 26 43 1 15 Frame plate 95 71 01 1 16 Spring clip 9 12 mm 05 24 55 3 17 Pressure spring 03 11 91 2 18 Refer to item 11 19 Washer 16 x 10 2 x 0 8 mm 04 01 43 6 20 Pressure spring 0 85 mm 43 11 12 2 21 Conductive bearing 10 mm 04 24 26 8 22 Refer to item 11 23 Sp
177. uring the power supply cover 25 on the front side Remove the two round head screws 27 securing the power supply cover on the rear side Take care of the crinkled washer 26 Tilt the power supply cover by pulling the front side in left hand side direction until the rear side clears the mains switch and then withdraw the power supply cover in the left hand side direction 510 02 10 rev 01 0 01 2002 service manual FPI 5000 I 1 9 Base cover Removal Remove the water tank as described in paragraph 1 2 Water tank Refer to figure 1 1 Unhook the envelope slide 5 and withdraw it Pull the envelope receiving tray 4 in the rear side direction and withdraw it Carefully turn the machine over and place it on the front side Take care not to trap the power supply lead and the connecting lead Remove the four hex head screws 31 securing the catch tray 30 and withdraw it Slacken the four hex head screws 22 securing the base cover 21 to both inside frames Shift the base cover in the left hand side direction to unhook it and then withdraw it 1 10 Transportation table Removal Open the loc as described in paragraph 1 1 Loc Remove the front cover plate described in paragraph 1 7 Front cover plate 10 figure 1 2 Refer to figure 1 2 Remove the two round head screws 6 with the washers 7 securing the transportation table on the front side and the two countersunk screws 1 securing it in the insert area Carefully pull the
178. uring the system initialisation and after switching the function off and on again the measured thickness of the first processed document is defined as the reference thickness If a following document appears to be too thick this error s generated Reset the DFC unit key 5 in the error screen n order to make a new reference 1 necessary Error 4 5 6 7 8 9 11 Message Feeding failure Action Check previous set Info Wrong reference The document appears to be too thick or a double feed occurred During the system initialisation and after switching the DFC function off and on again the measured thickness of the first processed document is defined as the reference thickness If a following document appears to be too thin this error is generated Reset the DFC unit key 5 in the error screen in order to make a new reference if necessary Error 4 5 6 7 8 9 12 Message Document stoppage Action Remove documents Info Document too long During the initialisation of the machine job information loaded into the system including the document lengths for each machine If the document length for one or more specific feeders appears to be too long this error is generated Error 4 5 6 7 8 9 13 Message Document stoppage Action Remove documents Info Paper jam The document that is processed by the indicated feeder doesn t leave the feeder Remove the paper and press the Reset key Now
179. utch will move The DC motor controlled mechanical subsystems collator area and the divert unit are independent of mechanical drive from the FPI 5000 I In the options Shunt forward and Shunt reverse the transport rollers for moving the documents to and from the shunt area in the case of multifeeds from one specific feeder will be activated The options Collator run in and Collator run out activate the DC motor for the transport of the documents into or out of the collator area If the divert option is selected the ejector menu of figure 3 21 will appear Here the optional ejector subsystem can be tested This subsystem is driven by a DC motor If the Ejector key 1s pressed the ejector finger will perform one cycle it moves forward and returns to its rest position afterwards If the Flap up key is pressed the flap will move to its upper position provided it wasn t already in that position If the Flap down key is pressed the flap will move to its lower position provided it wasn t already in that position The folding subsystem can be checked with the options Folding table 1 and Folding table 2 In this case the associated cam disk is activated once The option Folder activates both the folder and the shunt clutches In the second screen of the FPI 5000 C actuator the two four or six feeder clutches that are present can be checked Short explanation of the various actuators In order to analyse the results of the actuator tests it 15 relev
180. wait until the motor has been cooled down Error 1 38 Message Technical failure Action Call service Info DFC unit defective The DFC unit isn t working properly during the start of the machine See also error 36 Without DFC jobs working with a reference thickness cannot operate properly However jobs in which the DFC function is not used are not affected by this error Error 1 44 Message Technical failure Action Call service Info Loc sensor defective Photocell PH3 cannot be adjusted correctly The photodiode current resulting from the feedback control circuit is set at a too high value This message may be issued at startup during factory production testing or after field replacement of the photocell The photocell must be replaced by a more sensitive photocell 510 03 58 rev 01 0 01 2002 service manual FPI 5000 I Error 1 45 Message Technical failure Action Call service Info Flap sensor defective Photocell PH2 cannot be adjusted correctly The photodiode current resulting from the feedback control circuit is set at a too high value This message may be issued at startup during factory production testing or after field replacement of the photocell The photocell must be replaced by a more sensitive photocell Error 1 46 Message Technical failure Action Call service Info Track sensor defective Photocell PH1 cannot be adjusted correctly The photodiode current resulting from the feedback contro
181. with the FPI 5000 C A checksum error occurred Error 1 86 Message No connection Action Check device connector Info Communication failure The FPI 5000 I cannot communicate properly by SCS with the FPI 5000 C from which no PC acknowledge signal is received The upstream 12 pole system connector may be not correctly fitted or a hardware error occurred Error 1 87 Message No connection Action Check device connector Info Communication failure Too many communication retries Error 1 88 Message No connection Action Check device connector Info Communication failure Too many nack signals received Error 1 89 Message No connection Action Check device connector Info Communication failure The FPI 5000 I cannot communicate properly via the PC bus timeout error This may occur both in SCS and conventional PC communication Error 1 95 Message Sealing risk Action Check water level rev 01 0 01 2002 510 03 63 service manual FPI 5000 I Info Brushes too dry This warning is issued after each 2500 inserts and points to a possibly empty water container After pressing an arbitrary key the warning disappears Error 1 101 Message Envelope stoppage Action Remove envelope Info Cover open During the feeding of an envelope in the envelope track one or more FPI 5000 I covers are opened Error 1 102 Message Document stoppage Action Remove documents Info Cover open During the fe

service manual FPI 5000 I

Contents

Download Pdf Manuals

Related Search

Related Contents