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1. SMART FEEDER SERVICE MANUAL ISSUE 09 99 PARTS SECTION I PAGE 57 SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 58 191 26400 400 TOP MOUNT BAR CODE READER INDEX PART NUMBER DESCRIPTION 1 002B 08461 INTERLOCK EXTENDED 2 002B 08569 INTERLOCK SWITCH 3 005 27553 600 LASER HOUSING
2. SECTION I PAGE 55 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 56 088 26574 500 LASER SCANNER ASSEMBLY INDEX PART NUMBER DESCRIPTION 1 526 27172 500 SCANNER CABLE 2 007 26569 600 ANGLE BRACKET 3 007 26572 600 LASER MOUNT BRACKET 4 007 26573 600 SCANNER SLIDE 5 018 13750625 DOWEL PIN 375DIA 625LG 6 088 01MRB01302 LASER SCANNER 7 172 24280 ADJUSTING LEVER 8 320 26567 600 SLIDE BLOCK 9 320 26568 600 SLIDE ADJUST BLOCK 10 579 26570 600 SCANNER COVER 11 007 26571 600 MOUNT BRACKET 12 600C 20701 SCANNER HOUSING 191 26400 400 MOUNT BAR CODE READER EXISTING CABINET
3. YRGHI SYSTEMS CORP 5 MADE IN USA 042 08551 ASSY N 438 SERVICE MANUAL ISSUE 05 01 E 5b LED Indications The following LED indications apply only when using B H line code LED 1 LED2 LED 3 LED 4 Note ON OFF every second indicating operation except when LED 2 is lit ON indicates busy line code read taking place calibration read taking place or machine speed sample being done ON indicates line codes will be read using calibration data that has been stored OFF indicates line codes will be read without using calibration data that has been stored ON indicates line codes will be read using high tolerance read scheme OFF indicates line codes will be read using low tolerance read scheme LED s 1 4 are all turned on while the boot functions are being done All the lights will stay on if a problem is detected in the hardware of the line code reader card LED 5 LED 6 LED 7 LED 8 Input of lead edge detection sensor probe 1 sen
4. 709 26907 500 TOUCHSCREEN ASSEMBLY INDEX PART NUMBER DESCRIPTION 1 007 26618 600 CARD CAGE SUPPORT 2 007 26619 600 BRACKET DISK DRIVE 3 007 26895 600 MOUNT BLOCK 4 007 26896 600 MOUNT BRACKET 5 020 26879 600 DISPLAY MOUNT TUBE 6 027 27280 500 FAN ASSEMBLY 7 032 00015250 FUSE 1 5A 250V 8 042 26622 500 GBX OMR SBX ASSEMBLY 9 042 26746 000 CONTROLLER VGA amp FLAT PANEL 10 042 26750 500 144 BOARD CONFIGURATION 11 042 26908 500 SINGLE CHANNEL READ BOARD 12 042 26932 500 CIRCUIT BOARD CPU 486 13 042 ZT21009TFO CARD CAGE STD 32 14 042 ZTP101 POWER SUPPLY 15 067 27281 000 6 OUTLET SURGE SUPPRESSOR 16 320 26872 600 DISPLAY CLAMP 17 526 26742 000 CABLE FLOPPY DRIVE POWER 18 526 26747 000 CABLE FLOPPY 19 526 26749 000 CABLE MULTI PURPOSE 20 605 26412 400 SOFTWARE 21 709 26744 000 LCD TOUCH MONITOR 22 710 26743 000 DRIVE 3 5 FLOPPY SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 65 SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 66 186 0357006
5. 1 46 H nn T 003 04 TAR 5 u BRN 40 Pay ij w late 5 IED YEL GRN 7 l 1 L i 8 a 98K B P BLK 4 BED BLK 88K ANG 188 L S YEL J MW y 1 GRN BK r BIK RED pl RED 2 Lu 9 CRI H ORN 5 BLU MODULE 6 B n NIT PANEL 0070 08155 0020 08156 F INSERTER CON DB37F 1 INSERTER CONN SEE NOTE 4 REFERENCE REF NO lv vv v v Y Y Y X Y Y Y Y Y Y IARAARANAAN
6. X uis isa nn y 1 m E d 220 D ftit 1 erit N G S NH E U TO EDER a HE iNT 4 N 580 27508 500 CONTROL PANEL ASSEMBLY INDEX PART NUMBER 8 0 002 08523 002 08524 002 08525 002 08537 002 08541 0020 08138 020 RN00620416 020 RN00620425 020 RN00820416 025 A218VN 026 ABMMA 026 030 SMODC5 030 SMIDC5 042 PB24SM 045 018135 045 222135 045 22202A 046 4285011B 051 0476350 173 VBM1062 526 27509 500 600A 17923 600B 22454 600D 19050 438 SERVICE MANUAL DESCRIPTION READER 5V CABLE CABLE 91 ASSEMBLY CABLE 90 ASSEMBLY P9 CABLE ASSEMBLY KEYBOARD CABLE INTERCONNECT BOARD STANDOFF ROUND 1 LONG STANDOFF ROUND 46 32 X 1 56 STANDOFF ROUND 1 LONG RING LUG 8 TY WRAP AN
7. 0020 08135 POWER UNIT BOX INDEX PART NUMBER 1 002B 08521 2 024 213406253 3 030 1240D25 4 030 2KUMP14D182 5 031 24200 6 032 00005250 7 032 00015250 8 032 00030250 9 032 00040250 10 032 01120250 11 032 00150250 12 032 10020250 13 035 H320B 14 037 609505 1 15 039 67293001 16 039 88010641 17 044 ECV24N48 18 044 VL30341011 19 050 24206 20 050 20R6 21 067 V130LAZOA 22 067 V33ZA5 23 173 2192 24 600B 17246 25 600D 17897 26 600D 19051 438 SERVICE MANUAL DESCRIPTION METER ASSEMBLY TERMINAL STRIP SOLID STATE RELAY RELAY SPDT 24VDC SOCKET RELAY 11 PIN FUSE 1 2 FUSE 1 AMP FUSE 3 FUSE 4 AMP FUSE 12 AMP FUSE 15 AMP FUSE 2 AMP POWER INLET SOCKET CONNECTOR CONNECTOR RECEPTACLE POWER SUPPLY POWER SUPPLY LINE FILTER 10 AMP EMI FILTER 20 AMP VARISTOR VARISTOR BUMPER BRACKET COVER PANEL ENCLOSURE ISSUE 05 01 PARTS SECTION I PAGE 9 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 10 091 26702 500 ADAPTOR PLATE ASSEMBLY EN _ 52 24 7
8. 549 26603 500 FEEDER ASSEMBLY page 1 INDEX PART NUMBER 1 002A 22091 2 002B 08526 3 002 08630 4 002 21905 5 600 15839 003 025 25947 500 002 19633 002 08462 6 0020 08522 7 0020 17505 8 002 08570 9 014 10262216 10 016 50500075012 016 505000750010 11 018 26512 600 12 020 RA010C0608 13 002B 08157 14 123 8AL 15 095 25212 600 16 112 200DBA30637 17 112 26300 500 18 113 S290XL100 19 320 26217 600 438 SERVICE MANUAL DESCRIPTION PULLEY FEEDER MOTOR ENCODER OUTSIDE FEED BELTS MIDDLE TIE PLATE STATIC BRAID BEARING BLOCK GROUND WIRE FEEDER ELECTRICAL ASSEMBLY CREEPER CONVEYOR ASM SENSOR MODULE HEX HEAD BOLT 10 32 X 1 SHIM 5ID 75OD 12THK SHIM 5ID 75OD 010THK DOCKING PIN SPACER 10C 5LG BRAKE COLLAR SHAFT CLUTCH HARDENED PULLEY TIMING 30T PULLEY ASSEMBLY BELT TIMING TAN DOOR MOUNT BLOCK ISSUE 05 01 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 547 25937 500 547 27279 500 592 26208 600 592 26209 600 600A 17661 600A 21521 600B 15839 014 600B 15839 017 600B 15839 028 600B 15839 060 600B 15839 125 600B
9. CREEPER CONVEYOR e e FEEDER 438 HD SERVICE MANUAL 071 26938 400 Layout of Model 438 Figure ISSUE 05 01 INTRODUCTION SECTION A PAGE 438 HD SERVICE MANUAL ISSUE 05 01 071 26938 400 Feed Belt The Main Feed Belt is a one inch wide yellow timing belt which drives the bottom sheet of paper under the singulator roller Also called Singulator Belt Auxiliary Feed Belts These are two blue urethane belts located either side of the main feed belt The auxiliary feed belts assist the main feed belt smoothing variations in frictional drive correcting erratic feeding of the paper Drive Rollers These two orange rollers are located directly below the singulator These are used in conjunction with the singulator to ensure only one sheet is fed at a time AUXILIARY FEED BELTS DOUBLE DETECT SENSOR D INTRODUCTION SECTION A PAGE 4 Feeder Section Figure Paper Level Detector This demand switch monitors the paper going into the feeder area It s job is to limit and demand the amount
10. 411 438 SERVICE MANUAL ISSUE 01 01 PRINTED WIRING BOARDS SECTION E PAGE 9 SECTION MACHINE SCHEMATICS Schematic Page 438 SCHEMATIC 2 438 SCHEMATIC 3 438 SCHEMATIC 4 438 SCHEMATIC 5 470 BULK LOADER 6 FOLDER AC DC 7 FOLDER ACCUMULATOR 8 FOLDER SYSTEM 1 AC DC 9 AC DC CONTROL CABLE 10 438 SERVICE MANUAL ISSUE 05 01 MACHINE SCHEMATICS SECTION F PAGE 1 2 lt 2 gt C BK RM k 5 BLK yy BIK If f 5 WHT 3 6 06 e m 2 8 1213415 D c 3 WI I 1D C b lt 6 BIK
11. Tee a E INSERIER CABLE FROM ADAPTOR TN 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 59 SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 60 088 2768
12. 041 26521 500 DISCONNECT SWITCH ASSEMBLY INDEX PART NUMBER 8 0 438 SERVICE MANUAL 005 264 17 600 007 26416 600 024 10300226 024 25065 024 25384 000 024 25385 000 024 26509 600 024 26526 000 026 26523 000 041 26527 000 041 26530 600 041 26689 000 526 26755 500 526 26756 500 526 26757 500 529 26415 600 DESCRIPTION ENCLOSURE MOD BRACKET END CLAMP TERM BLOCK JUMPER BAR COMB TYPE TERM BLOCK NEUTRAL TERM BLOCK GROUND DIN RAIL TERM BLOCK END COVER STRAIN RELIEF CONNECTOR HANDLE DISCONNECT SWITCH SHAFT DISCONNECT MOD DISCONNECT SWITCH MAIN POWER CABLE FOLDER POWER CABLE FEEDER POWER CABLE CLAMP ISSUE 05 01 PARTS SECTION I PAGE 41 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 42 502 26799 500 FOLDER ELECTRICAL DRAWER MOD 15 502 26799 500 FOLDER ELECTRICAL DRAWER MOD INDEX PART NUMBER 50 12 13 14 15 16 17 18 438 SERVICE MANUAL 024 10300226 024 26020 000 024 26787 000 024 26526 000 024 26789 000 024 26790 000 024 26791 000 025 25816 000 025 25817 000 030 26793 000 030 2CAD14D10 031 3
13. 438 SERVICE MANUAL JESBURE SENSOR ISSUE 05 01 PARTS SECTION I PAGE 47 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 48 750 26525 500 WIDE TRANSPORT CONVEYOR page 2 INDEX PART NUMBER 1 002 17309 0028 08408 0028 18366 0028 19599 0028 08409 6008 18635 014 91264 249 016 0375062512 016 05000750031 016 0630087506 019 200037 020 01020630 020 RA010C0604 112 S6A320H3712 112 S6A320NF037 126 SC37 153 FB683 158 5 55 526 26327 500 584 26310 600 600 16342 001 600 16349 031 600 16349 034 600 17224 600 17697 600 17700 600 17733 600 17735 DESCRIPTION IDLER ROLLER ASSEMBLY BRAKE ASSEMBLY CONVEYOR DOCKING PORT ASM CLUTCH SHAFT ASSEMBLY CLUTCH ONLY SHAFT ONLY BOLT SHOULDER 10 24 SHIM 3751D 6250D 12THICK SHIM 5001D 7500D 031THICK SHIM 0631D 8750D 06THICK RING EXTERNAL STANDOFF 10 32 1 875LG SPACER 10CL 25LG TIM
14. Transfer Conveyor Figure ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 42 D 6f Transfer conveyor s outfeed guides position is recommended that the Transfer conveyor arm be positioned parallel to the deck of the inserter and it should be close enough to the deck so the outfeed guides do not need to drastically deflect the folded document This will help prevent the flat green belts from creeping and ease the extraction force required to remove the folded document SMART FEEDER eee GOOD POSITION POOR POSITION PACK TOO LOW POOR POSITION PACK 0 69 Fold quality Consistent fold quality is required or the package size can vary enough to cause the Transfer conveyor packages to be improperly positioned in the conveyor D 6h Transfer conveyor package spacing problem If package spacing problems occurs in the Transfer conveyor it should be purged of all the remaining documents in it This will insure that documents will be properly positioned D 7 POWER UNIT REFER TO SECTION POWER UNIT SCHEMATIC The Power Unit is located inside the cabinet and consists of the following components 1 Master Relay Electric safety interlock switch 2 Fuses Fuse tips illuminate when the fuse is bad 3 Solid State Relays SSR For switching high power items motors etc 4 5 VDC Power Supply
15. sene eee sena 13 CACA Mathias B uerle GmbH gt Gewerbehallestr 7 11 D 78112 St Georgen nS Tel 07724 882 0 Fax 07724 882 111 Serviceline 49 7724 882 250 E Mail center mb bauerle de MATHIAS B UERLE Spare Parts Accumulator 38 438 SERVICE MANUAL 02 01 SECTION J 071 26938 400 1 ACCUMULATOR VIEW 2030866 2029470 2030867 2029471 1123011 Gx 1143011 330 MSx8 DIN 912 3012205 4 1 5 8 DIN 912 2029424 1143039 4x M8x25 DIN 12 2001432 4 1143011 2x MSx8 DIN 912 A IgE 1150018 2x 1 1 1033165 4005229 4x 1027342 8x1 2017496 4005236 2022502 2x FI 1017555 2 2022500 2 HH 2016814 d jew 1 X GE L 7 PEA 200139 2001468 2 E 1143007 MSx10 DIN 912 201160 2 1027480 2 1112025 2x 690122 DIN 625 2001455 2030855 2012752 4x 1143056 8 M4x6 DIN 912 438 SERVICE MANUAL 02 01 071 26938 400 2017494 2 1 MERE 1033166 8x 4002556 4x m 1107002 2x A4 3 DIN 125 1143003 2 8 DIN 912 as 12001476 2x 1112013 6002 22 DIN 625 2012754 1110013 9x1 DIN 471 772006618 1107001 AB 4 DIN 125 1143019 2 DIN 912 1112005 6000 22 ON 625 1033095 2 1 2051604 4 1
16. The demand switch monitors the paper through a metal The Feed Belt provides the primary force separating a wand On the top of the wand is spring loaded hex head sheet from the bottom of the shingled stack The setup adjustment bolt which when turned raises and lowers the procedure for this belt is described below The Feed wand Belt tension adjustment knob is factory set limited to Raise the wand to allow more paper to fed into approximately 3 4 turn This is adequate operator the feeder adjustment for typical paper weight variations If the Lower the wand reduce the amount of paper Feed Belt is replaced E T 1 Loosen the long set screw 3 32 on the top ADJUSTMENT en stop collar of the Feed Belt tension knob shaft ia iT 2 Lay a straight edge across the top of the Feed i ES belt lengthwise Make sure it lays across both 1 pulleys 3 Adjust the Feed Belt tension knob so 3 16 inch H k Feed Belt deflection is possible in the middle of 7 the belt 4 Now turn the Tension Knob 3 8 turn CCW 5 Slide the stop collar to the top of the Tension Knob shaft Position collar so the long set screw is perpendicular to the side frame Tighten set screw to the Tension Knob shaft This will again limit adjustment to 3 4 turn Singulator and Paper Demand Figure ri
17. N NU X10 INTERLO INTERLOCK UN 9 9 9 9 9 FOLDER El BU BLK 121 BK BK 15 WET BRN AK 12 AA D 10488 fi ON aLK M a T aK ACCUMULATOR PK en BN 10 BK N LEFT RACK 18 INP LEFT RACK 1 INPUT RACK oyo TO IBl 1 BU BLK BLK
18. PS N 2 3 IN _ BR ys P d ED 8 LN 2 A A 2 S 2 3 3 E 1 1 2 I 0 5 E 3 S AL gt 3 lt S c3 un 4 fo d 2 NZ c NIL 17 v NL CM 2 2 FRONT VIEW 091 26702 500 ADAPTOR PLATE ASSEMBLY INDEX PART NUMBER 00 40 438 SERVICE MANUAL 002B 07723 002B 07724 526 26700 500 025 43125VN 025 B398VN 025 523 035 8301213 039 2058173 045 13165 526 27525 500 526 26701 500 600 19109 001 091 26673 600 DESCRIPTION CABLE CONVEYOR MOD 4 CABLE MOD 7 CABLE POWER SWITCH FEMALE Q D 1 4 RING CRIMP 8 MALE CONNECTOR DUAL Q D POWER INLET FEMALE SCREW LOCK WIRE GREEN 16 GA CABLE RS 232 SERIAL CABLE ACCUMULATOR FOLDER BLANK CONN PLATE PLUG ADAPTOR PLATE ISSUE 05 01 PARTS SECTION I PAGE 11 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 12 549 26603 500 FEEDER ASSEMBLY page 1
19. 27 REPAIR CHECKOUT PROCEDURE FOR ACCUMULATOR DUMP 7 28 REPAIR CHECKOUT PROCEDURE FOR TRANSFER CONVEYOR INFEED 41 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 3 438 SERVICE MANUAL ISSUE 05 01 D 1c Systems Checks Switch the 438 power ON The Feeder motor starts Y N Close all covers Perform the Feeder Speed is Too Slow RCP Press the CYCLE key on the Operator Control Panel momentarily A document is fed through the singulating area to the 438 Y N Perform the Paper Could Not Be Fed RCP Press the CYCLE key on the Operator Control Panel for about 1 second A continuous stream of documents is fed to the 438 Y N Perform the Paper Jam in Feeder RCP With the 438 in CYCLE mode the creeper conveyor supplies documents when needed Y N Perform the Creeper Conveyor Motor RCP Adjust the Paper Level Detector REPAIR INFORMATION SECTION D PAGE 4 0 2 FEEDER FUNCTION D 2a Description A paper hopper supplies the bottom fed friction feeder continuously while the operator loads paper from the top It has 4 mounts 2 each side with set screws in which the hopper slides The creeper conveyor comprises two black rubber belts driven by a motor located on the bottom side of the hopper Controlled by a paper level detector the motor is activated when the detector activates the paper demand switch The two
20. BLK BLK 200 CIR KER INT ON INTERCONNECT ul ND jet BLK BN 24 WHT BLU 23 CRA BR Y Y m N BRN 27 BRN 25 BRN 26 474 4453 BRN 18 29 DELIVERY 80 GRN YE 2 PILE DIRECTION 281 2 BU 1 LEFT D PILE DIRECTIO 82 _ CRN YE GRN YEL 6 R e 16 8 X2 6 I 0 7 9 gt ik e m gt u gt 5 BLK ET BLK p EG ak 210 Id Ire epe WA 01 INA UA NO
21. e 1 Service BUESA fm MP LUE qp HD gU IU d 2 H 2 Purchased Components Manuals cti ep onec cete tameu LE MEL ED 2 JEngitisertng Valles A cute LR at 3 Fed Typical Postal Metering Setup Presets iri jet iebes 6 438 SERVICE MANUAL ISSUE 05 01 MISCELLANEOUS SECTION H PAGE 1 438 SERVICE MANUAL ISSUE 05 01 MISCELLANEOUS SECTION PAGE 2 H 1 Service Bulletins Technical Bulletins for your machine regarding software updates product updates and safety issues will be sent to you whenever necessary H 2 Purchased Components Manuals Model 30 Hardware Operations Manual The Accu Sort Model 30 Scanner is used to read bar code 438 machines with bar code capabilities are shipped with the Model 30 Scanner manual from Accu Sort Systems Inc 511 School House Road Telford PA 18969 H 3 Engineering Values Eng Software Version Number Prior Rev 26412 028 01 20 20 Acc Feed Settle Time Time msec after trail edge of last page passes Accumulator stack sensor into Accumulator until Accumulator clutch is fired 02 70 10 70 10 Acc Dump Done Time Advance Feed Time msec from Accumulator is going to dump until next feed is started short value advance feeds before the pack moves from the Accumulator A longer time allows pack movement detected at the Accumulator prese
22. A 0020 08137 g To 33 v Ty REFERENCE TABLE MODULE 1 FEEDER MODULE 2 FOLDER MODULE 5 POWER UNIT MODULE 4 C MODULE LLL y MODE Oe MODULE 6 ACCU MODULE 7 INSERTER 4 MODULE 8 NFED DENT PB 245M RIGHT 4 9 J un 31 ES 5 i 22 31 o amp pod m 410 400 8 2 8 ar ETT FROM INTERLOCK SENSE 11 sw 18 Br 40 m 7 55 CEN DEM DIES hoo C BITO BAH STR 0808 3 EEN 17115 ETSI CEL 20806 Y MI MOULE Er BH 24 REN MIE SN ap ANAAL om un 080 8 an 2080 7 ET DEL A BTS 06 a ET ABT
23. CONNECT TO SOLENOID CONNECT TO POINT WITH GREATEST NEGATIVE POTENTIAL PROBABLY SOLENOID WHT BLK BRN gt CONNECT THESE TWO WIRES IN SERIES WITH STATION 6 ERROR DETECT SWITCH CONNECT POINT WITH GREATEST POSITIVE POTENTIAL EUR CONNECT TO POINT WITH GREATEST NEGATIVE POTENTIAL CONNECT TO POINT IN THE CIRCUIT THAT WILL GENERATE A MACHINE ERROR WHEN GROUNDED TA CONNECTION BETWEEN MOISTENER CONTROL SWITCH AND MOISTENER SOLENOID BREAK CONNECTION CONNECT TO SWITCH CONNECT TO POINT WITH GREATEST POSITIVE POTENTIAL PROBABLY SWITCH OTHER SIDE OF CONNECTION BROKEN ABOVE CONNECT SOLENOID CONNECT POINT WITH GREATEST NEGATIVE POTENTIAL PROBABLY SOLENOID IN CONNECTION BETWEEN FLAP DETECT ERROR CIRCUIT AND GROUND BREAK CONNECTION CONNECT TO POINT WITH GREATEST POSITNE POTENTIAL NHT BLK BLU OTHER SIDE OF CONNECTION BROKEN ABOVE MUST BE CIRCUIT GROUND SEE NOTE 2 MITT VUST BE CIRCUIT CROUND en CONNECTION BETWEEN ENVELOPE CONTROL SWITCH AND ENVELOPE SOLENOID BREAK CONNECTION CONNECT TO SWITCH CONNECT TO POINT WITH GREATEST POSITIVE POTENTIAL PROBABLY SWITCH ER SIDE ECTION BROKEN ABOVE MUST BE CIRCUIT GROU oa MONEE OEN ABONE CONNECT SOLENOID CONNECT TO POINT WITH GREATEST NEGATIVE POTENTIAL PROBABLY SOLENOID CONNECT THESE TO WRES ACROSS PONT IN THE CIRCUIT THAT WLL PROVDE VOLTAGE WEN CONNECT TO POINT WITH GREATEST POSITI
24. 17 Not Used 18 Not Used 19 Not Used 20 Not Used 21 Not Used 22 Not Used 23 Not Used 438 SERVICE MANUAL ISSUE 05 01 PROBLEM ANALYSIS SECTION PAGE 5 438 SERVICE MANUAL 2 GENERAL SOLUTIONS ERRORS Many error codes are the result of jammed paper physical errors or paper expected at specific time and location read errors sequence blank page misprinted code etc The sensors index the number of sheets as they pass incrementing a count on the CPU 486 If a corresponding decrement of count does not occur from the next sensor a read error is generated If error persists consider failure of sensor or communication problem poor connection etc For many read errors check that setup parameters are correct before pursuing functional troubleshooting Read errors require a determination of the integrity of the pack The operator must look at the readings on the display and manually verify each sheet When read errors occur it indicates that the integrity of the package is in question The 438 was not able to verify a page while stream feeding a package When the operator is satisfied that the package is complete press the DUMP key to release the package Once a reading error BLANK or MISREAD is declared additional feeding via the CYCLE key will continue to display BLANK or MISREAD errors but will not stop the machine ISSUE 05 01 PROBLEM ANALYSIS SECTION C PAGE 6 Before poweri
25. b A L A gt EAN 7 LJ ION AR 2 p gt NN Ad 538 26297 500 AUXILIARY DRIVE ASSEMBLY INDEX PART NUMBER 1 007 26292 600 2 007 26293 600 3 007 26294 600 4 007 26295 600 5 020 26296 600 6 095 26291 600 7 095 26382 600 8 095 26387 600 9 112 200DOA20637 10 112 200DOA30637 11 112 26311 600 12 113 200116037 13 158 S3PPG4 14 600 16349 034 15 600 16349 027 438 SERVICE MANUAL DESCRIPTION BRACKET AUX GEAR IDLER SUPPORT BRACKET AUX DRIVE INSIDE BRACKET AUX DRIVE OUTSIDE STANDOFF GEAR SHAFT DRIVE SHAFT STUB SHAFT PULLEY 20T PULLEY 30T PULLEV 22T TIMING BELT BALL BEARING HUB CLAMP SPUR GEAR ISSUE 05 01 PARTS SECTION I PAGE 39 438 SERVICE MANUAL ISSUE 05 01 041 26521 500 DISCONNECT SWITCH ASSEMBLY PARTS SECTION I PAGE 40
26. 21 C 3h 19xxx EngValue 21 31 20xxx 5 21 IKK AAA Pa e 21 438 SERVICE MANUAL ISSUE 05 01 PROBLEM ANALYSIS SECTION C PAGE 1 438 SERVICE MANUAL 1 TEST SCREEN OPERATION Diagnosis of the system begins with these tests If it is found that the displayed information indicates a problem refer to the schematics in section D or section F Tender Max Aret Talali 2122 Press Power in Stari Test 26 Xtnp Tork Speed Test Pressing the green Power On switch on the keyboard will start the feeder and folder motors and display the speeds of the feeder folder transfer conveyor and read encoders ISSUE 05 01 PROBLEM ANALYSIS SECTION C PAGE2 Touch Setup Factory use only cancel to exit screen E Left Up Right Lou Left a B amp B amp q a amp Q Test Cycle Press Test Cycle for 100 msec On 300 msec Off cycle Press Test Cycle again to stop test The speeds indicated are approximate inches per second NOTE The FEED and READ speeds must be within 596 of each other to ensure normal operational condition 10 144 Board Inputs Outputs Use this screen to test inputs and outputs e The name of the output or input will
27. See Section K for MB Folder parts manual 703 26611 500 FOLDER MOD page 2 INDEX PART NUMBER NOOR WD 10 11 12 13 14 15 438 SERVICE MANUAL 021 SB4375 021 5 625500 024 26781 500 025 25817 000 041 26739 500 041 26820 500 070 26797 500 095 26900 600 113 200160037 186 034007658 526 26740 500 526 26741 500 526 26796 500 538 26297 500 579 26518 600 579 26519 600 DESCRIPTION SNAP BUSHING SNAP BUSHING TERMINAL BLOCK ASSEMBLY FERRULE 22 AWG MAGNETIC SWITCH INTERLOCK SWITCH ENCODER STUB SHAFT MOD TIMING BELT FOLDER MB see Section K D C CONTROL CABLE CONTROL CABLE INTERLOCK SWITCH EXT CABLE AUXILIARY DRIVE ASSEMBLY COVER HAT COVER MOD ISSUE 05 01 PARTS SECTION I PAGE 37 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 38 538 26297 500 AUXILIARY DRIVE ASSEMBLY 54 N NS AN N en EN
28. J 3 Aa BELT ADJUSTMENT Belt Adjust Figure 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 7 438 SERVICE MANUAL ISSUE 05 01 Singulating Roller The Singulating Roller creates a precise singulating gap There are three critical adjustments required to get a precise singulating gap These adjustments are Vertical Position of Singulating Roller Singulating Roller parallel with lower rollers e Occasional rotation of Singulating Roller Position of Singulating Roller The position of the Singulating Roller with respect to the two rollers on the lower shaft is critical This spacing creates the singulating gateway The setup process is as follows 1 Place one sheet of paper under the singulator 2 Lower the Singulating Roller so one sheet of paper can not pass under the roller Use chrome knurled knob 3 Slowly raise the Singulating Roller using the adjusting knob 4 Attempt to pull the document out while slowly raising the Singulating Roller with the chrome knurled knob 9 When the document starts to move as you firmly pull it under the Singulating Roller proper singulation adjustment is achieved 6 Load the singulation area with paper and test feed paper 7
29. 10 24 SUPPORT DOCKING SUPPORT DOCKING SUPPORT HINGE STANDOFF 6CL 187LG SNAP BUSHING TERMINAL BLOCK ASSEMBLY FERRULE 22AWG MAGNETIC SWITCH ASSEMBLY INTERLOCK MAGNET A S SENSOR ASSEMBLY BRAKE HANDLE ACCUMULATOR MB see section J D C CONTROL CABLE CONTROL CABLE RECEPTACLE BELT COVER GEAR COVER COVER ACCUMULATOR BELT COVER PLATE MOD THUMBSCREW ASM 250 20 X 5 CLUTCH LOWER INFEED GUIDE TOP BELT LOWER BELT ISSUE 05 01 PARTS SECTION I PAGE 31 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 32 024 26724 500 TERMINAL BLOCK ASSEMBLY 024 26724 500 TERMINAL ASSEMBLY INDEX PART NUMBER 00 4 09 438 SERVICE MANUAL 007 26675 600 024 10300226 024 11511607 024 11836816 024 25821 000 024 25822 000 024 25824 000 024 25825 000 024 26022 000 024 26023 000 024 26723 000 035 25809 000 035 25810 000 035 26030 000 057 26721 500 067 26722 500 194 25606 605 DESCRIPTION MOUNTING BRACKET END STOP TERMINAL BLOCK END SECTION SPACER PLATE SPACER COVER RIGHT END COVER LEFT TERMINAL BL
30. goes through Paper Level Detect switch also called demand switch SW15 to SSR4 Does the Creeper Motor go on when the level switch is closed Y N Make sure that SW15 is closed and that no emergency switch is open Check fuses F1 and F2 Check wiring between the LF4 and creeper motor The power is applied to the AC outlet then to SSR4 when rack 1 opto 2 LED is lit in the 438 Is there voltage at the connector that feeds the motor when the RESET ON key is pressed Y Check fuse F2 Is it good the fuse Enter Test function Select Speed from the menu Activate the Feeder motor does the motor run and LED of opto 2 on opto rack 1 light Y N L Check relay SSRI Make sure the speed pot 1 set Check for 120 across the line side of LF4 Check for 90VDC across the terminals of the creeper motor Are these voltages present Y N Replace 4 creeper motor Paper is fed through the Feeder as the Feed Clutch fires Y N Replace the Feed Clutch 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 13 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 14 REPAIR CHECKOUT PROCEDURE FOR FEEDER SPEED ENCODER Enter the TEST menu from the VIP display Select INPUT from the submenu and select Feeder Speed Encoder input Turn the machine by hand and listen for a beep indicating encoder state is changing Y N Check
31. i On L LU I T 4 C al al I 1 1 NOT CONV USED PIGTAIL WIRE COLOR DESCRIPTION OF CONNECTION NOTES FOR INSERTERS WITH D C CONTROL AN C4 ey BL CONNECTION BETWEEN STATION 2 CONTROL SWITCH AND STATION 2 SOLENOID BREAK CONNECTION CONNECT SWITCH CONNECT TO POINT WITH CREATEST POSITIVE POTENTIAL PROBABLY SWITCH BR OTHER SIDE OF CONNECTION BROKEN ABOVE CONNECT SOLENOID CONNECT POINT WITH GREATEST NEGATIVE POTENTIAL PROBABLY SOLENOID OR gt CONNECT THESE TWO WIRES IN SERIES WITH STATION 2 ERROR DETECT SWITCH 5 CONNECT TO POINT WITH GREATEST NEGATIVE POTENTIAL CONNECTION BETWEEN STATION 3 CONTROL SWITCH AND STATION 3 SOLENOID BREAK CONNECTION CONNECT TO SWITCH CONNECT TO POINT WITH GREATEST POSITIVE POTENTIAL PROBABLY SWITCH EN 6 ON fi CONNECT SOLENOID CONNECT TO POINT WITH GREATEST NEGATIVE POTENTIAL
32. Advance Feed Switch 1 allows the next pack to be started when the Accumulator is supposed to dump plus the Accumulator Dump Time 0 starts the next pack after Accumulator Presence Sensor is cleared plus the Accumulator Dump Time Comm Hardware Type 0 Ziatech 1 WinSystems Eng Values Password 4444 Default 9561 is backup Eng Values Enable Password 1 Enable Default 0 Disable This enables disables password to access Engineering Values Max Exit Demand Power On Cycles Default Number of inserter demand cycles before 438 outputs a package Bar Read Commport cycle machine power after changing setting 1 CPU 2 Serial ISSUE 05 01 MISCELLANEOUS SECTION H PAGE 5 438 SERVICE MANUAL ISSUE 05 01 MISCELLANEOUS SECTION H PAGE 6 Envelope Flap Detect On at 010 4 Typical Postal Metering Setup Presets Off at 350 Insert Sta 1 The following are Typical Presets for the 438 configured Ink Marking On at 010 for 6 Station AC DC Open Feed Inserter Control with two Off at 010 postal meters Meter 2 and Meter 3 Meter 1 and Meter 2 Insert Sta 00 This may vary from your actual application Postal Meter Divert On at 200 First Meter inline when Meters 1 and 2 Test Setup tested Double Detect ON Off at 010 Presets Reset NA Insert Sta 07 Lower Left Display OMR Logical Shift Enable at 090 Lower Right Display OMR Bad Package Stop Enable at 080 No Use Timeout OFF Number of Inser
33. 24 RETA EN EN T BIS 17 12 CUN MOBI UM MODULE TAL 25 BRN BK lt 9 5 S T gt PUNE BK RETURN ER PLANE AUX GND B amp H 24 RET 80 9 Id LAR CLUTCH 1 1 1 2 221 2 un NC WC 52 NC NC WHT c RH 9 RET gt 2 2 90 DISC SENS WHT WHI JUMPER ASM RED 3 N BER 2 1 ORN we J RED RED RED 58k
34. XE 0964007 X7 202 2 0471002 SECTION 1 02 01 438 SERVICE MANUAL 071 26938 400 5 EJECTOR ROLLERS 4006688 4 438 SERVICE MANUAL 02 01 SECTION J 071 26938 400 6 RIGHT SIDE VIEW Il 2029423 1143011 220 1107003 2x 1143007 2x 1107003 2x 2028216 2 1150010 4x LL 2051810 4x 1143004 8x M4x10 DIN 912 nn 2051606 2 1118004 2 8 DIN 913 1143004 2 4 10 DIN 912 2051605 2x 2051803 1103029 2x M3x10 DIN 84 2017495 2x 1143006 2x 5 16 DIN 912 1107003 2x 5 3 DIN 125 2029464 2x 2029465 2 1017572 2x 1081022 4x 2022697 2 438 SERVICE MANUAL 02 01 SECTION J 071 26938 400 7 RIGHT SIDE VIEW Il 1001014 4005224 4005231 2x 1033094 2x __ 2029448 4005226 2x 2036183 1011044 12x 1011004 4x 2022501 2 1122003 2x 5 DIN 934 1143006 2x 5 16 DIN 912 1150011 4x 4x20 DIN 6325 1013058 2x 1118009 4x 5 DIN 913 4005750 2051806 4005750 2036247 1143007 4 438 SERVICE MANUAL SECTION J 071 26938 400 8 LEFT SIDE VIEW 2029450 1108007 4x 810 DIN 127 2001390 4x 1143028 4x M10x25 DIN 912 4005757 2x 1133010 2x BZ 4 DIN 6799 1033014 1107001 8 4 DIN 125 1122002 8 DIN 934 2012734 1143004 2x M4x10 DIN 912 1112025 69
35. 00000000000 6 El Ku WHITE 1 t 9 OE i S S ME RACK 0 1 Rack 2 is located on the floor of the cabinet behind Onto Racks 0 and 1 438 SERVICE MANUAL ISSUE 05 01 PROBLEM ANALYSIS SECTION PAGE 3 438 SERVICE MANUAL Rack Opto 0 00 Input Feed Sensor 0 01 Input Stack Sensor 0 02 Input Feeder Speed Encoder 0 03 Input Folder Speed Encoder 0 04 Input Demand Switch 0 05 Input Inserter Deg Encoder 0 06 Input Conv Option Line 0 0 07 Input Conv Option Line 1 0 08 Input Key Power 0 09 Input Key Cycle 0 10 Input Key Dump 0 11 Input Interlock 0 12 Input Transfer Conv IN SNS 0 13 Input Transfer Conv OUT SNS 0 14 Input Inserter Home Encoder 0 15 Input Conv Option Line 2 0 16 Input 2 Sheet Sensor 0 17 Input Folder Sensor 0 18 Input Acc Sensor 0 19 Input Cutter Busy Signal 0 20 Output Acc Dump Clutch 0 21 Output Transfer Conv Clutch 0 22 Output Transfer Conv Brake 0 23 Output Acc Dump Brake ISSUE 05 01 PROBLEM ANALYSIS SECTION C PAGE 4 Rack Opto 1 00 Outp
36. Pross Dacin Kay To Start EXTRA PAE Poser Off Power Of eU Fir OI Mer OI INSTALLATION SECTION A PAGE 13 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION PAGE 14 KEYBOARD OPERATION CYCLE DUMP EMERGENCY STOP Press to shut down all motors on the 438 in emergencies Lifting any cover will also shut down all motors on the 438 POWER ON Press to start all motors and enter ready mode Press while in ready mode to shut down the 438 CYCLE Press quickly to feed one sheet Repeat until EOG on display is 1 DUMP Press and hold CYCLE to start continuous feeding DUMP Press after manually filling the accumulator to discharge package into the folder 7 SETUP SCREENS Press Setup while in the Run screen GOR Systens 438 HD SERVICE MANUAL 071 26938 400 ISSUE 05 01 This screen provides access to all 438 setup screens Press Run to return to the Run screen Note Normal factory settings are in bold font Job not functional at this time A 7b System Package Count Reset Sheet Length 5 5 NT 7 NT 8 5 11 4 5 6 Package Size e Max Pages in Accumulator 1 to 12 e For Read 1 greater than max expected 5 for the LineCode test set Or number of fixed pages w
37. SECTION I PAGE 71 SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 72 186 035700600 3208 DOCUMENT LOADER page 4 186 035700600 3208 DOCUMENT LOADER 4 INDEX PART NUMBER DESCRIPTION 1 1 033 088 BELT 2 1 027 447 ROLLER 3 1 017 504 BUSHING 4 1 017 541 BUSHING 5 2 017 098 RIGHT SHAFT 6 2 017 091 LEFT SHAFT 7 1 031 090 FLAT BELT 8 4 005 032 SIDE UNIT COMPLETE SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 73 SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 74 186 035700600 3208 DOCUMENT LOADER page 5 186 035700600 3208 DOCUMENT LOADER page 5 INDEX PART NUMBER DESCRIPTION 1 1 029 937 TRANSFORMER 2 4 005 097 PC MB VERSION 4 005 098 PC GBR VERSION 3 1 027 190 MOUNTING BRACKET PCB 4 4 004 419 SPEED CONTROL 220V 4 004 420 SPEED CONTROL 1 15V 4 005 102 MOTOR 220V 4 005 101 MOTOR 110V SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 75 SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 76 186 035700600 3208 DOCUMENT LOADER page 6 186 035700600 3208 DOCUMENT LOADER 6 INDEX PART NUMBER DESCRIPTION 1 4 005 099 HOLD DOWN COMPLETE 2 1 031 089 BELT 3 4 005 033 ROLLER 4 4 005 033 ROLLER 3 512 190 LEAF SPRING 5 1 029 910 PHOTODETECTOR 6 1 027 427 KNURLED SCREW 7 2 028 091 BRACKET SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I P
38. ta 14 POWER ON 14 nacen Re PERDE RIBERA 14 DUMP ana pane n eR 14 SETUP SCREENS ssesnnonezazennenzenzensensenzonseneennensonsensensensensensensensensensen 15 Job not functional at this 15 IN ND a SYSTE Testo N 15 ASIC Feeder Setup nr Re Er 16 17 18 Cvyr Transfer 18 Infeed ouem eR 19 Line Read 19 BQH Read ae 19 GBR Read RU e REOR 19 Bar Read RUE NER REOR MEE 20 InSeFtet eorr ERR OO 20 Inserter Setup AAA a a eere 21 438 HD SERVICE MANUAL 071 26938 400 ISSUE 05 01 Inseitet Setup 1 cie tote er en e Ere 21 Inserter Setup 25a otn cnet acer e rete nn 22 Inseitet Set p 34 oie oco titles terrent cots e OR Eee rede 25 A 7k Engineering Values Password Protected sss 25 71 EXICOMM A 26 8 GBR LINE CODE READ SYSTEMS 27 RN 27 Reader Board Values that can be Adjusted Through The 438 Touchscreen 27 A 8b Setting Up the GBR Line Code Reader 21 11 28 Setting the Probe zen RU 28 A Sc 438 Line Read Setup Screens sss eee
39. 2036183 PLATE 2036184 PLATE 2036247 PLATE 2036248 PLATE 2041183 SCREW 2051604 STOP 2051605 MOUNTING BRACKET 2051606 BLOCK 2051607 BLOCK 2051803 RAIL 2051806 ROD 2051810 BAR 2051847 PLATE 3012205 KNURLED SCREW 3500015 SET SCREW 3501069 COLLAR CPL 3504014 SET SCREW 4002556 TRANSPORT ROLLER 4005227 PULLEY 4005229 PULLEY 2046216 TIMING BELT PULLEY 4005231 GEAR 4005233 PULLEY 4005236 TIMING BELT PULLEY 4005237 TIMING BELT PULLEY 4005750 TIMING BELT PULLEY 4005960 CLAMP 4006394 SPRING ELEMENT 2006511 STUD 2006647 STUD 4004630 PULLEY 2012573 PULLEY 2001785 BUSHING 1031204 FLAT BELT N Rl 03 00 BIR A 5 Re 5 PR Hm Halle DIDI 2 438 SERVICE MANUAL 02 01 071 26938 400 SECTION J 15 2017833 1 2017834 1 2022429 WASHER 4 2030932 LEVER 1 2030933 LEVER 1 2030934 BRACKET 1 2031061 BRACKET 1 2031062 BRACKET 1 2001842 SLEEVE 2 2001843 SLEEVE 1 2001845 SLEEVE 1 2030452 COVER 1 2052134 BEARING PLATE 2 2029175 COVER 2 2031666 1 1011065 ROLLER CHAIN 2 2
40. GO CONTENTS 438 Service Manual ISSUE 05 01 438 SERVICE MANUAL ISSUE 05 01 COVER 071 26938 400 B ma 438 SERVICE MANUAL ISSUE 05 01 COVER 071 26938 400 B ES 071 26938 400 While every has been taken the preparation of this manual no liability will be accepted by GBR Systems Corporation arising out of any inaccuracies or omissions All service documentation is supplied to GBR Systems Corporation external customers for informational purposes only GBR Systems Corporation service documentation is intended for use by certified product trained service personnel only GBR Systems Corporation does not warrant or represent that such documentation is complete GBR Systems Corporation does not represent or warrant that it will notify or provide to such customer any future changes to this documentation Customer s service of equipment or modules components or parts of such equipment may void any otherwise applicable GBR Systems Corporation warranties If Customer services such equipment modules components or parts thereof Customer releases GBR Systems Corporation from any and all liability for Customer s actions and Customer agrees to indemnify defend and hold GBR Systems Corporation harmless from any third party claims which arise directly or indirectly from such service Prepared by GBR Systems Corporation Technical Publications Copyright 2001 by GBR Systems Corporation rights re
41. Lower lip advanced Small buckle space setting knob Lower lip set back Large buckle space setting knob Thin paper grades Advance lower lip Heavy paper grades Set back lower Accordion Fold It is possible that heavy paper grades get stuck and form a so called accordion fold In such a case the fold plates must be set back Loosen the Allen screws 6 2 both sides of the fold plate Set back the fold plate using the scale 7 Tighten the Allen screws Change the fold stop plate by the same amount REPAIR INFORMATION SECTION D PAGE 37 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 38 Creasing When special types of paper are folded deviations from the nominal values may become necessary Individual corrections can be made by means of the numbered setting knobs at each roller The fold rollers and delivery shafts with the matching setting knobs are arranged according to the following scheme Roller 1 is the feed roller Roller 2 makes the 1 fold Roller 3 makes the 2 fold Roller 4 makes the 3 fold Roller 5 makes the 4 fold Roller 6 makes the 5 fold Roller 7 makes the 6 fold Roller 8 is the delivery shaft This layout sketch shows a fold unit with 6 fold plates An additional scale 2 indicates adjustments of 0 5 mm gt Rollers 6 amp 7 are not part of the fold units with 4 fold SENNO eR C
42. 005 27522 500 CABINET ASSEMBLY i ll e ES A EN 209 9 29 FEN ASA T Y i HE w ELI 005 27522 500 ASSEMBLY INDEX PART NUMBER 1 002B 07742 2 002B 0851 1 3 002B 19707 4 0020 08135 5 580 27508 500 6 020 26565 600 7 027 4 551 8 041 4LTGU0511TR 9 091 26702 500 10 172 CR7300 11 526 26700 501 12 526 26700 502 13 526 26700 503 14 600A 13967 15 600A 17632 16 600A 17921 17 600A 18996 18 005 27147 600 19 600B 1943
43. 0375062512 016 05000750031 019 26549 600 019 200037 020 01020630 020 RA010C0604 112 S6A320H3712 112 S6A320NF037 126 SC37 153 FB683 158 5 55 526 26327 500 584 26310 600 600 16342 001 600 16349 031 600 16349 034 600 17224 600 17697 600 17700 600 17733 600 17735 600 17742 DESCRIPTION IDLER ROLLER ASSEMBLY BRAKE ASSEMBLY CONVEYOR DOCKING PORT ASM CLUTCH SHAFT ASSEMBLY CLUTCH ONLY SHAFT ONLY BOLT SHOULDER 10 24 SHIM 3751D 6250D 12THICK SHIM 5001D 7500D 031THICK RETAINING RING RING EXTERNAL STANDOFF 10 32 1 875LG SPACER 10CL 25LG TIMING PULLEY 20T TIMING PULLEY 20T SET SCREW COLLAR BEARING 3751D 50D RADIAL BEARING TRANSPORT CABLE INFEED GUIDE CLAMP COLLAR SPUR GEAR HUB CLAMP DRIVE ROLLER BEARING DRIVE PULLEY COLLAR RIGHT PIVOT STOP UPPER ROUND BELT 600A 17785 600A 18200 600A 18568 600B 17689 600B 17743 600B 17744 600B 17745 600B 17746 600B 17747 600B 17888 600B 18165 600B 18639 600B 18640 600B 18642 600B 18643 600B 18644 600B 18645 600B 18646 169 26556 600 600B 18648 600B 17693 600B 18650 600B 19304 600B 19305 144 26615 600 320 26548 600 522 26547 600 177 27369 500 LEFT PIVOT STOP CLUTCH STOP MOUNT BLOCK NIP ROLLER IDLER LOWER ROUND BELT UPPER IDLER BELT LOWER DRIVE BELT LOWER EXIT BELT UPPER EXIT BELT PAPER GUIDE TRANSPORT WIRE GUARD SHAFT SHAFT DRIVE SHAFT SHAFT DRIVE SHAFT NIP WHEEL PIVOT BAR TIE BAR SUPPO
44. 2 Buffered transfer conveyor where nest folded document s are placed in an open inserter feed gripper arm station 3 3 Transfer conveyor where the nest folded document s are presented to the gripper arm 0 55 Fold Principle The folder works on the buckle fold principle using a fold plate and fold rollers Fold rollers 1 and 2 drive the sheet into the fold plate until it comes up against the adjustable stop The trailing edge ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 30 of the sheet continues to be advanced by the roller and the sheet is buckled The sheet is now grasped by fold rollers 2 and 3 Note The fold rollers are made of polyurethane foam material Do not wash the rollers with any cleaning fluid This will destroy the anti static coating and folding problems will occur Clean using a stiff brush but no liquids of any kind The rollers pull the folded sheet out of the fold plate and the pair of fold rollers and carried to the next fold plate After the last fold the sheet is transferred by the delivery rollers to the delivery belt Fold Roller Diagram Figure D 5c Components of the Fold Unit Components and operating elements of the fold units 1 Noise covers 2 Paper thickness measuring device 3 Fold roller adjustment knobs 4 5 Handwheel 6 Main switch 438 SERVICE MANUAL ISSUE 05 01 D 5d Fold Plate Positions In the fold unit 38 4 there are four positions for the fold
45. D 2 FEEDER FUNCTION 5 D2a Descripcion HM 5 D 2b Timing Procedures ec doris ars 5 D 2c Feeder Setup and Adjustments seen 6 D 3 Repair Checkout Procedures RCP 12 D 4 ACCUMULATOR SECTION 4 204 0 4 4 44 lt 25 sia eH rai 25 2 46 Accumulator Clutch and Brake Adjustments 25 D 4c Accumulator Dump Roller Replacement 26 D 5 FOLDER FUNCTION 30 D sctpton eese RO USUS UHR 30 Hold Principles edoren e e EN mee 30 D 5c Components of the Fold 31 D 5d Fold Plate Positions 31 D 5e Position the Fold Plates and 32 D 5f Setting the Fold Length 38 sese 32 D 5g Close Fold Plate 38 se 33 D 5h Setting the 33 D 5i Setting the Fold Roller 35 D 5j Fine Adjustments and Corrections 36 D 6 TRANSFER CONVEYOR 40 D 6a 40 Db ERU REO EU 40 D 6c X Exit sensor Test on the Transfer conveyor 40 D 6c Exit sensor Test on the Transfer conveyor 41 D 6d 438 configuration of Exit sensor module ss 41 438 SERVI
46. On 1 1 Begin 07 Length 16 6 A LSB First Off Low EOG 00 NOT EOG 00 Begin 5 Length 3 1 7 Begin 2 Length 3 1 4 10 Length 6 6 At Line 0 At Line 0 Count Size 0 At Line 0 At Line 0 Repeat 0 MISCELLANEOUS SECTION H PAGE 7 438 SERVICE MANUAL ISSUE 05 01 Read Bar Job Setup Job 41 Stop for Read Errors Yes READ LINEREAD to SETUP Menu Postal Meter Divert Enable Postal Meter 1 May operate from a read mark as before Consult the 420 Operating Manual MISCELLANEOUS SECTION H PAGE 8 1 Station 7 Select Default 2 Station 8 Select 3 Inserter E Stop 4 Station 1 Error 5 Station 7 Select Inverted Signal 6 Station 8 Select Inverted Signal 7 Inserter E Stop Inverted Signal 8 Station 1 Error Inverted Signal Select Postal Meter Divert Enable to operate Postal Meter 3 from a Lineread mark Select Postal Meter Divert Enable OFF to operate from Weights TEST to INSERTER to TIMING Menu Postal Meter Divert Postal Meter 1 e Enter Meter in degrees 0 to 350 e Enter Meter OFF in degrees 0 to 350 Enter Meter Position STA 1 to 12 after envelope insert station Postal Meter 2 Enter Meter ON in degrees 0 to 350 Enter Meter OFF in degrees 0 to 350 Not Enter Meter in degrees 0 to 350 Enter Meter OFF AT
47. Page Env Wts Engineering Values Password Protected Page Enter the weight of the individual page the 438 will sum the weight of all pages automatically Env Enter the weight of an individual envelope Ins 1 4 Wts and Ins 5 8 Wts Enter the weight of each insert in stations 1 4 and stations 5 8 Inserter Setup 3 Number Value For settings refer to Section H Misc for the Engineering Values List Refer to Section H 4 for an example of a Typical Postal Metering Setup Preset 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION A PAGE 25 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION A PAGE 26 ExitComm Type 0 No Comm 1 RR Donnelly 1 2 RR Donnelly 2 3 Pinnacle 1 4 Pinnacle 2 5 General 6 Tampa 1 7 Zaandam 1 Start Button Xmits test data in type selected Displays response terminated by a CR LF Press again to stop Event List 8 GBR LINE CODE READ SYSTEMS OPTION A 8a Introduction The Line Code Recognition System is capable of decoding line code marks that are on 1 10 1 8 or 1 6 spacing There can be as many as 25 mark locations in a bank with a possibility of two banks per each channel of Line Code marks A Single Line Code Recognition card supports input information from two probes The second probe is an optional feature The system is limited to having only one of the two probes active at any one time If more than one channel of Lin
48. The Accumulator Sensor indicates presence or absence of a package the It also monitors package discharge M nn o o mimis when the dump clutch has been engaged 2 g Stack Sensor Located at the edge of the ramps the stack sensor indicates the dU du dp document has cleared the stacking ramps Sensor Modules 9 2 m HI The Sensor Module for the Accumulator and Stack Sensors are accessible by removing the right side accumulator cover 5 Accumulator Section Figure A 3c FOLDER SECTION The folder is capable of placing 1 to 4 folds in a C Z V or double V configuration It is fed by the Accumulator Section Buckle Plates Manual adjustable plates which set the distance of the fold from the edge of the paper Rollers Used to nip the paper as it is buckling creating the fold Folder Drive Motor A motor which drives all folder
49. Y N Agjust the transport belts 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 27 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 28 REPAIR CHECKOUT PROCEDURE FOR ACCUMULATOR SENSOR ACCUMULATOR SENSOR REFER TO SECTION ACCUMULATOR Enter the TEST menu from the display Select INPUT from the submenu and select Acc Sensor input Repeatedly block the accumulator presence sensor with your hand or a piece of paper As the sensor is blocked the audible beep is heard and opto 0 18 opto module 18 on opto rack 0 red LED illuminates each time the sensor is blocked and goes out when the sensor is unblocked Y N Check a different input to ensure the audible signal on the display is working Y N Check input opto 0 18 opto module 18 on opto rack 0 Does LED light when sensor is blocked Y N Check the wiring between the accumulator sensor and the opto rack If the wiring required correction does this correct the problem Y N Check the pico fuse of the opto module Replace the input opto module if necessary and repeat the test Does the LED illuminate Replace the CPU 486 PWB Check the stack sensor REPAIR CHECKOUT PROCEDURE FOR ACCUMULATOR DUMP CLUTCH ACCUMULATOR DUMP CLUTCH REFER TO SECTION F ACCUMULATOR Enter the TEST menu from the VIP display Select OUTPUT from the submenu and select Acc Dump Clutch output Repeatedly press the ENTER key and note whether th
50. in degrees 0 to 350 Not Used Enter Meter Position STA 1 to 12 after envelope insert station Enter Meter Output Point Option 1 Station 7 Select 2 Station 8 Select Default 3 Inserter E Stop 4 Station 1 Error 5 Station 7 Select Inverted Signal 6 Station 8 Select Inverted Signal 7 Inserter E Stop Inverted Signal 8 Station 1 Error Inverted Signal Used Postal Meter Weights e Enter Meter Position STA 1 to 12 after envelope insert station Enter Meter Output Point Option Meter 1 to 2 Weight Value 00000 to 60000 Meter 2 to 3 Weight Value 00000 to 60000 Weight Page Enter Page Weight Value 00000 to 60000 e Enter Envelope Weight Value 00000 to 60000 Weight Inserts 1 2 3 4 Enter Insert gt 1 Weight Value 00000 to 60000 Enter Insert gt 2 Weight Value 00000 to 60000 Enter Insert gt 3 Weight Value 00000 to 60000 Enter Insert gt 4 Weight Value 00000 to 60000 nn Weight Inserts 56 78 Enter Insert gt 5 Weight Value 00000 to 60000 Enter Insert gt 6 Weight Value 00000 to 60000 Enter Insert gt 7 Weight Value 00000 to 60000 Enter Insert gt 8 Weight Value 00000 to 60000 Operation e Package Weight less or equal lt to Meter 1 to 2 Weight Value e Meter 1 operates e Package Weight greater than Meter 1 to 2 Weight Value and less or equal lt to Meter 2 to 3 Weight Value Meter 2 operates Package Weight greater than Meter
51. nn010 nnO1 1 nn012 nn013 nn014 nn015 nn016 017 018 019 INVALID NOT ENOUGH NV RAM PRESETS CORRUPT NV RAM FAILED DUAL PORT RAM FAILED INVALID COMMAND INVALID PIC INT INVALID SETUP DATA PARITY ERROR 438 SERVICE MANUAL Similar to Group Out of Range error page range must be within 1 7 Invalid command Cycle machine power The program has run out of non volatile ram You should never get this error If you do get this error either the software is bad or the cpu board is bad Some of the preset parameters have fallen out of their defined maximum or minimum range If new EPROMS were just installed this error might occur If this is the case ignore the error If the battery jumper was pulled from the cpu board this error might occur If this is the case install the battery jumper and ignore the error If neither of the previous scenarios happened the cpu board is probably bad Data in the non volatile ram was changed Power to the CPU was unplugged directly at the board Noise in the 120 VAC power Hardware failure on reader board Battery failed or battery jumper missing Bad CPU 186 board Hardware failure on reader board Battery failed or battery jumper missing Bad CPU 186 board Hardware failure on reader board Battery failed or battery jumper missing Bad CPU 186 board Reader board memo
52. plates Position 1 e Position Position 2 Qu Delivery Rollers Position 4 Fold Rollers Fold Roller Diagram Figure REPAIR INFORMATION SECTION D PAGE 31 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 32 D 5e Position the Fold Plates and Deflectors The Fold plates and deflectors have one lock screw 1 each at the left and right hand side Insert the fold plates and deflectors in such a way that the lock screws 1 fit in the recesses 2 in the frame of the fold unit Secure the fold plates and deflectors by tightening the lock screws D 5f Setting the Fold Length UFT 38 Loosen the lock scew for the paper stop 3 Set the stop to the required position on the scale 5 by turning the adjustment wheel 4 Secure the fold plate stop by turning the lock screw clockwise By turning the fine adjustment screw 6 the fold length can be adjusted precisely with the machine running Adjustment by means of the fine adjustment screw is only possible when the lock screw for the fold plate stop has been tightened Byturning the knurled knobs of the adjustment wheel 1 it is possible to make angle corrections of the paper stop for example if the paper is out of square The combination fold plate 38 has fold plate infeed section with an adjustable lower lip This means that the space available to form the buckle can be modified depending on the thickness and the stiffness of the
53. 005 3 144 27060 500 4 002 20917 5 002 08526 6 0020 16435 7 0020 18099 8 007 26214 600 9 008 1131 4 10 016 26219 600 11 020 01021013 12 057 26856 500 13 095 25212 600 14 104 1 5 24 15 110 26576 600 16 112 200DBA16637 17 112 200DBA18650 18 112 200DBA30637 19 112 20000 30637 20 112 26300 500 438 SERVICE MANUAL DESCRIPTION PULLEY THUMBSCREW 8 32 5LG UPPER PAPER GUIDE LOWER PAPER GUIDE FEEDER MOTOR SINGULATOR ASSEMBLY SINGULATOR COVER ASM BRACKET HANGER PLASTIC KNOB CLIP SENSOR MOUNT STANDOFF 10 32 812LG DOUBLE DETECT amp FEED SENSOR SHAFT CLUTCH HARDENED WORM GEAR TENSIONER BAR PULLEV TIMING 16T PULLEV TIMING 18T PULLEV TIMING 30T PULLEV TIMING 30T PULLEV ASSEMBLV ISSUE 05 01 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 112 26311 600 113 20008003712 113 200090037 113 200190037 113 200290037 126 SSC25 152 B683 153 FB6103 167 125375 186 492813591 320 26332 600 547 25937 500 580 26544 500 592 26210 600 592 2621 1 600 600A 16556 600A 18200 600B 17312 600B 17666 600B 22223 122 27256 500 PULLEY MOD BELT TIMING 40G BELT TIMING 45G BELT TIMING BELT TIMING COLLAR BEARING FLANGE BEARING WOODRUFF KEY EXTENDED TENSIONER ASM MOUNT BLOCK LEFT FEEDER CHASSIS KEYBOARD ASSEMBLY LEFT GUIDE SHOE RIGHT GUIDE SHOE WORM GEAR ASM CLUTCH STOP FEEDER MOUNT BAR TENSION ADJUST ADAPTOR PLATE FRICTION CLUTCH PARTS SECTION I
54. 014 08251103 014 10221116 014 08251106 014 10221106 014 0621112 016 004 016 104 016 110 016 00600 016 10600 041 35701 046 27157 500 095 27150 600 112 200DOA14625 112 200D0A28637 113 200110037 129 27151 600 158 5 55 320 27152 600 026 026 271 27146 400 526 27622 500 ISSUE 05 01 DESCRIPTION INTERLOCK SWITCH MOUNT BRACKET SHCS 4 40 X 375 SHSS 88 32 X 187 SHCS 10 32 X 1 00 SHCS 8 32 X 375 SHCS 10 32 X 375 SHCS M6 X 12mm WASHER FLAT 4 WASHER LOCK 4 WASHER LOCK 10 WASHER FLAT M6 WASHER LOCK M6 INTERLOCK MAGNET CABLE DEMAND SWITCH SHAFT SENSOR PULLEV TIMING 1 5P 14T PULLEV TIMING 1 5P 28T BELT TIMING 1 5P 11PL ADAPTER SHAFT PULLEY BEARING FLANGETTE MAGNET BLOCK TIE WRAP ANCHOR TIE WRAP TECHNICAL BULLETIN not shown SERIAL CABLE not shown SECTION I PAGE 88 NOTES 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 89 SECTION J ACCUMULATOR ACCUMULATOR TOP VIEW ml e e e e e 2 INPUT SIDE TOP VIEW san 3 EJECTOR SIDE see 4 INPUT SIDE VIEW AAA RA 5 EJECTOR ROLLERS 6 RIGHT SIDE VIEW LU 7 RIGHT SIDE VIEW Lom 8 EEFTSIDE M DAE 9 CLUTCH BRAKE iii A 10 BALL BEARING EJECTOR 5 00 11 FLAT BELT DRIVE LEFT INPUT 12 ACCUMULATOR PARTS 18
55. 12 600 15839 119 13 600 15915 025 14 600 17921 15 600 18200 16 600 15839 068 438 SERVICE MANUAL DESCRIPTION BEARING BLOCK INTERLOCK ASSEMBLY CUP WASHER E RING STANDOFF 10 32 X 2 RADIAL BEARING BUMPER SPRING RIGHT FRAME ADAPTOR PLATE GUIDE BUSHING TRACK BUTTON INSERT ADJUSTMENT SCREW GROUND SCREW CLUTCH STOP TRACK BUTTON ISSUE 05 01 PARTS SECTION I PAGE 19 PARTS ISSUE 05 01 SECTION I PAGE 20 438 SERVICE MANUAL 002D 16435 SINGULATOR ASSEMBLY 22 d Hirt qu 0020 16435 SINGULATOR ASSEMBLY INDEX PART NUMBER 438 SERVICE MANUAL 002B 08212 002B 16325 002B 16326 002C 16500 014 SW15 181 03000301000 181 05000808125 600 16435 003 600 16435 004 600 16435 005 600 16435 006 600 16914 600 15915 044 600 16431 600 16435 002 600 16435 007 600 16435 008 600 16435 009 DESCRIPTION CREEPER CONVEYOR SWITCH INPUT BRACKET INFEED SWITCH BRACKET SUPPORT BAR ADJUSTING SCREW SPRING SPRING ADJUSTING SCREW ROLLER AXLE DETENT WAND PAPER DET
56. 2 to 3 Weight Value Meter 3 operates 438 SERVICE MANUAL ISSUE 05 01 MISCELLANEOUS SECTION H PAGE 9 438 SERVICE MANUAL ISSUE 05 01 MISCELLANEOUS SECTION PAGE 10 Notes SECTION I PARTS 738 26206 500 438 TOP ASSEMBLY 2 005 27522 500 CABINET 4 580 27508 500 CONTROL PANEL 5 6 0020 08135 POWER UNIT A C 8 091 26702 500 ADAPTOR PLATE ASSEMBLY 10 549 26603 500 FEEDER ASSEMBLY page 1 12 549 26603 500 FEEDER ASSEMBLY page 2 14 547 25937 500 LEFT SIDE CHASSIS ASSEMBLY 16 547 27279 500 RIGHT SIDE CHASSIS ASSEMBLY 18 0020 16435 SINGULATOR 20 002B 21905 OUTSIDE FEED BELTS eese 22 0020 08522 FEEDER ELECTRICAL ASSEMBLY 24 0020 17505 CREEPER CONVEYOR 26 580 26544 500 KEYBOARD ASSEMBLY 28 702 26612 500 ACCUMULATOR 30 024 26724 500 TERMI
57. 4 007 26347 000 SLIDE PILE 5 007 26398 600 COVER SUPPORT 6 007 26569 600 ANGLE BRACKET SCANNER 7 007 26572 600 BRACKET LASER MOUNT 8 007 27377 600 BRACKET SIDE MOUNTING 9 007 27554 600 BRACKET LEFT DOOR 10 007 27555 600 BRACKET RIGHT DOOR 11 007 27571 600 SUPPORT BAR 12 007 27572 600 SWIVEL BLOCK 13 007 DLH1154 HINGLE 14 008 27575 000 CLAMP KNOB 15 014 31862220 BOLT 312 18 x 1 25 16 018 13750625 PIN DOWEL 375DIA x 625 17 026 ABMMA TIE WRAP ANCHOR 18 041 35701 MAGNET INTERLOCK 19 042 27623 500 QUAD SERIAL I O BOARD 20 088 01MRB01302 LASER SCANNER 21 169 27376 600 SLIDE BAR 22 172 24280 LEVER ADJUSTING 23 172 26388 000 HANDLE 24 172 27574 000 CLAMP HANDLE 25 320 26567 600 SLIDE BLOCK SCANNER 26 320 26568 600 SLIDE ADJUST BLOCK SCANNER 27 526 27172 500 TOUCHSCREEN SCANNER CABLE 28 579 26393 600 FEEDER COVER 29 579 27556 600 LEXAN DOOR 600C 20701 HOUSING SCANNER 088 27684 500 SINGLE CHANNEL DOUBLE PROBE READ See 0000000000000 Ud SECTION A ee _
58. Code Read with Setup Screens Laser Bar Code Read w Setup Screens SECTION B PREVENTATIVE MAINTENANCE SECTION C PROBLEM ANALYSIS Test Screens General Solutions to Problems Error Codes Possible Causes of Errors SECTIOND REPAIR INFORMATION Repair Checkout Procedures Feeder Accumulator Folder Section Transfer Conveyor SECTION E PRINTED WIRING BOARD INFORMATION SECTION F MACHINE SCHEMATICS SECTIONG INTERFACE TO OPTIONAL EQUIPMENT Connecting to an Inserter SECTIONH MISCELLANEOUS SECTION I PARTS SECTION J MB ACCUMULATOR SECTION K MB FOLDER 438 SERVICE MANUAL ISSUE 05 01 COVER 071 26938 400 B 3 438 SERVICE MANUAL ISSUE 05 01 COVER 071 26938 400 B 438 SERVICE MANUAL ISSUE 05 01 COVER 071 26938 400 B m 2 HEADERS 5 The information listed along the left edge refers to the machine the manual type and the number and revision level for that manual The particular issue listed in the center is an internal tracking device The top line of information along the right side states the title of the particular section The bottom line lists the section and the page number within that section 3 LIST OF CHANGES IN THIS REVISION 438 Service Manual 071 26938 400 Rev B Issue 05 01 ECN 7483 Previous release Rev A Changes incorporated in this manual Section Change A 3a Changed auxiliary feed belts to blue from red Singulator removed color description a
59. FED Clear the paper that was jammed in the machine and remove any obstructions Are mechanical settings correctly made Y N Check the wiring and connections for intermittent connections Adjust the singulator roller Adjust the auxiliary feed belts Check the paper guides ensure that the paper passes under the sensor Ensure that the drive pulleys are tight Check the feed clutch Are the lights on the Feed Sensor illuminated Y N Place one sheet of the current stock in the sensor area and adjust the sensor so that the red LED goes out with the sheet blocking the sensor Check that printing on the stock is not interfering with the sensor Does the LED on opto 1 light when one sheet is under the sensor Y N Check the small fuse for opto relay 1 Check the optical relay Is there 24 VDC at TB2 1 and TB2 2 Y N Check the connection from the controller to the Feeder Check the wiring e Check the power supply Clean the sensors Do the LEDs come on Y N Enter diagnostic Routines Select display status of Feed Sensor input 0 0 Does digital input change ON with the sensor blocked by one sheet of paper Replace the sensor Check wiring between the Control Box and keyboard Are there breaks or poor connections Y Replace the CPU Correct the wiring REPAIR PROCEDURE FOR FEEDER MOTOR When the 438 is powered creeper power is supplied to the Feeder AC outlet J2 of the power supply box
60. If more than one sheet is fed lower the Singulator two knob clicks If after adjusting as many as five knob clicks proper feeding is not obtained then all of the setup procedures for the singulator should be reviewed REPAIR INFORMATION SECTION D PAGE 8 NOTE Proper singulator adjustment depends on paper variables such as stock finish and environmental factors Specific adjustment on every job will be different Adjust the singulator roller as paper runs to get best setting Set Singulating Roller Parallel to Lower Rollers The precise gap created by the Singulating Roller and the two lower rollers must be equivalent for both of the rollers The procedure for testing and making the adjustment is described below Note This adjustment is normally done only when a new Singulating Roller is installed It should not be adjusted experimentally i e without need 1 Cut two strips of paper from the same document approximately 1 2 x 8 2 Put them between the two lower rollers and the large Singulating Roller 3 Adjust Singulating Roller until light tension is felt on the paper between the rollers 4 Check that the tension on both strips of paper is the same If it is not the same then adjust the geometry of the Singulating Roller 5 Loosen the 10 32 x 5 8 socket head cap screws 4 on the side rail or the back of the singulator plate Adjust either to best advantage 6 Carefully position the singulato
61. Line Read Setup 3 Group Seq and Page Seq Min and Max ITEM COUNT Choose when the first sheet in a package indicates the total number of sheets in that package No page sequence There is a limit of three Page Sequence marks Their purpose is to give an individual identity to each page within the package The maximum number of pages in a package is seven Page Sequence marks must be present when using PAGE SEQUENCING Ink Mark Meter Divert Parity Mark Not available at this time Subset Mark The limit of sheets into the accumulator is seven Subset is a special line in the code that is used to indicate whether a set is more than seven pages When the package is more than seven pages the machine will use the subset line to break the total page count into the amount of packages necessary to complete the total count This prevents possible damage to the folder from packages greater than seven pages The set and subset will go out in different envelopes Random Mark Blank Stop Press OK 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION PAGE 31 438 HD SERVICE MANUAL ISSUE 05 01 071 26938 400 Line Read Setup 2 Setup gt Line Read gt Setup 2 No Windows Currently this must be set to 1 Lines Inch The code marks can be at 1 6 1 8 or 1 10 inch spacing This is 6 8 or 10 lines per inch There can be as many as 25 mark locations in a bank EXAMPLE G
62. Of Group mark The machine will demand feed on EOG but all other documents in the set should have the NOT EOG mark LAST PAGE When this option is selected the system looks for the end of group mark demand feed on the last page of a set to be fed into the accumulator This option is intended for use with page sequencing configured as down Press Cancel to void any changes made to this screen or Ok to set the changes and return to the Line Read Setup 0 screen INSTALLATION SECTION A PAGE 29 438 HD SERVICE MANUAL 071 26938 400 GROUP SEQUENCE UP Choose if the group is counted UPward 1 2 3 4 Sets must be in order DOWN Choose if the group is counted DOWNward 4 3 2 1 Sets must be in order MATCHING will match marks within a set All marks in the set must be the same Sets may be in random order SAME ID NONE No group sequence The purpose of the Group Set mark is to ensure pages from two different packages do not get processed in a single package Group Set marks must be present when using GROUP SEQUENCING ISSUE 05 01 INSTALLATION SECTION A PAGE 30 PAGE SEQUENCE PAGE UP Choose if the page is counted UP 1 2 3 4 PAGE DOWN Choose if the page is counted DOWN 4 3 2 1 ROLL UP Cycle counts up sequentially to a selectable value set in Line Read Setup 3 Group Seq and Page Seq Min and Max ROLL DOWN Cycle counts down sequentially from a selectable value set in
63. Optional can be eliminated by operator configuration of the machine However when a data field is eliminated package security and integrity suffers Subset Mark Random Mark Press OK Line Read Setup 4 Setup gt Line Read gt Setup 4 1 Turn on the 438 press the SETUP button then press the LINE READ button Select GBR Press OK Press LINE READ again Press SETUP 4 a Take a piece of the stock that is going to be run through the machine and hand feed it until the light beam is on a white portion of the paper b Press WHITE The system will indicate that when it is done 6 Press BLACK and slowly move the paper until a black bar is under the light 7 Press BLACK a second time when the voltage reaches 0 the black bar is directly under the light 8 Remove the paper from under the light and press TRIP a Event list will say finished when done TRIP POINT 1 value should be between 40 and 150 OFFSET 1 should be between 100 and 250 If these values are not obtained go to section A 8b and reset the probe 9 Find the average of the recorded OFFSET 1 and 2 values 10 Change OFFSET 1 and 2 value to this average value by pressing the or keys example OFFSET 1 129 OFFSET 2 111 average 120 set both OFFSET 1 and 2 120 11 Change GAIN to O 12 Record these settings in the area to the right In the future this procedure can be eliminated
64. PAGE 15 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 16 547 25937 500 LEFT SIDE CHASSIS ASSEMBLY 547 25937 500 LEFT SIDE CHASSIS ASSEMBLY INDEX PART NUMBER 1 002A 17929 2 013 0104 3 014 025031116 4 016 712 5 019 100062 6 158 5 55 7 173 2194 8 181 3600401000 9 547 25934 600 10 600 15839 012 11 600 15839 119 12 600 15915 025 13 600 15839 068 14 104 1 5 24 15 126 55 25 16 600 17666 438 SERVICE MANUAL DESCRIPTION BEARING BLOCK HEX 10 24 SHOULDER BOLT CUP WASHER E RING RADIAL BEARING BUMPER SPRING LEFT FRAME GUIDE BUSHING TRACK BUTTON INSERT ADJUSTMENT SCREW TRACK BUTTON WORM COLLAR 25 DIA TENSION ADJUST ISSUE 05 01 PARTS SECTION I PAGE 17 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 18 547 27279 500 RIGHT SIDE CHASSIS ASSEMBLY 547 27279 500 RIGHT SIDE CHASSIS ASSEMBLY INDEX PART NUMBER 1 002A 17929 2 002B 08569 3 016 712 4 019 100062 5 020 RA0 1020632 6 158 5 55 7 173 2194 8 181 3600401000 9 547 25935 600 10 584 27253 600 11 600 15839 012
65. PROBABLY SOLENOID VO gt CONNECT THESE TWO WIRES IN SERIES WITH STATION 3 ERROR DETECT SWITCH CONNECT TO POINT WITH GREATEST POSITIVE POTENTIAL in CONNECT TO POINT WITH GREATEST NEGATIVE POTENTIAL 7 CONNECTION BETWEEN STATION 4 CONTROL SWITCH AND STATION 4 SOLENOID BREAK CONNECTION CONNECT TO SWITCH CONNECT POINT WITH GREATEST POSITIVE POTENTIAL PROBABLY SWITCH ATHER e R Tus RUNE CONNECT TO SOLENOID CONNECT 10 POINT WITH GREATEST NEGATIVE POTENTIAL PROBABLY SOLENOID isl WITH PEATE E 1 WHT BR gt CONNECT THESE TWO WIRES IN SERIES WITH STATION 4 ERROR DETECT SWITCH CONNECT TO POINT WITH GREATEST POSITIVE POTENTIAL CONNECT POINT WITH GREATEST NEGATIVE POTENTIAL CONNECTION BETWEEN STATION 5 CONTROL SWITCH AND STATION 5 SOLENOID BREAK CONNECTION CONNECT TO SWITCH CONNECT TO POINT WITH GREATEST POSITIVE POTENTIAL PROBABLY SWITCH OTHER F 0r eo gt R ABOVE E ES a CONNECT TO SOLENOID CONNECT TO POINT WITH GREATEST NEGATIVE POTENTIAL PROBABLY SOLENOID VHT YEL ee WHT CR gt CONNECT THESE TWO WIRES IN SERIES WITH STATION 5 ERROR DETECT SWITCH CONNECT TO POINT WITH GREATEST POSITIVE POTENTIAL en CONNECT POINT WITH GREATEST NEGATIVE POTENTIAL WHT BL mm CONNECTION BETWEEN STATION 6 CONTROL SWITCH AND STATION 6 SOLENOID BREAK CONNECTION CONNECT TO SWITCH CONNECT POINT WITH GREATEST POSITIVE POTENTIAL PROBABLY SWITCH ATHER
66. SPRING 2 1011004 CHAIN LOCK 4 1013058 SPROCKET 2 1017555 GUIDE PLATE 2 1017572 BEARING BLOCK 2 1019321 WASHER 4 1027342 COLLAR 8 1027430 KNURLED NUT 1 1027462 KNURLED KNOB 1 1030284 SOLENOID HOUSING 1 1030285 CORE 1 1030342 ROTOR CLUTCH 1 1030343 CORE SECTION CLUTCH 1 1030344 SOLENOID SECTION CLUTCH 1 1033005 TIMING BELT 1 1033014 TIMING BELT 1 1033083 ROUND BELT 2 1033077 90XL 0 37 TIMING BELT 1 1033095 ROUND BELT 2 1033101 ROUND BELT 2 1033111 140 XL 0 37 TIMING BELT 1 1033165 ROUND BELT 8 1033166 ROUND BELT 8 1054012 5 20 OVAL HEAD SCREW 2 1056001 PRESS NUT 8 1056003 4 PRESS NUT 2 1059028 TEFLON BEARING 2 1081024 3X10 RIVET 4 1103011 M4X8 CYLINDER HEAD SCREW 4 1103019 M3X5 CYLINDER HEAD SCREW 2 1103029 M3X10 CYLINDER HEAD SCREW 6 1103039 5 8 CYLINDER HEAD SCREW 4 1107001 PLAIN WASHER 6 1107002 PLAIN WASHER 10 1107003 PLAIN WASHER 10 1107005 PLAIN WASHER 1 1108007 LOCKWASHER 4 1109006 WASHER 1 1110013 SAFETY CLIP 2 1110023 SAFETY CLIP 1 1110030 SAFETY CLIP 4 1112005 BALL BEARING 2 1112013 BALL BEARING 1 1112025 BALL BEARING 7 1112030 BALL BEARING 2 438 SERVICE MANUAL 02 01 071 26938 400 SECTION J 13 1118004 SET SCREW 1118009 SET SCREW 1118015 SET SCREW 1220001 COLLAR 1122002 HEXHEAD NUT 1122003 HEXHEAD NUT 1143003 M4X8 ALLEN SCREW 2 1143004 M4X10 ALLEN SCREW 14 1143006 5 16 ALLEN SCREW 12 1143007 5 10 AL
67. around the expected location of every Line Code Mark is a 1 2 print line zone where the Line Code mark is expected to be detected Between two Line Code marks there is a 1 2 print 438 HD SERVICE MANUAL 071 26938 400 ISSUE 05 01 line zone where a mark can not be detected without creating an error This ensures that all Line Code marks are exactly where they are expected Press OK INSTALLATION SECTION A PAGE 35 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION A PAGE 36 Line Read Setup 3 Setup gt Line Read gt Setup 3 GER Systems Line Read Setup 3 The reader must be told at what point in a code field it will see page group parity and inserts Depending on the code format this indicates when the field begins how many lines it consists of and the maximum value of the field This is crucial to proper reading and the operator should have a master code template that shows the location and value of each line in a code field If certain fields are omitted enter an arbitrary number not related to the specific code in that field Example Where the code is page field first and there are three lines for the page field the correct set up would be Begin 01 Length 03 Max value 7 Group Mark Ink Mark Purpose Identify each page as being a part of an individual package The sequential incrementing of the number ensures the document s printed sequence is mainta
68. by entering these values directly 13 Press APPLY to download these parameters to the read System and then press 14 The reader setup is complete Line Read screens SETUP 1 2 and 3 must be completed before running paper 438 HD SERVICE MANUAL ISSUE 05 01 071 26938 400 NOTE When switching between probes or after the 438 has been switched off it may be necessary to repeat this setup procedure NOTE VALUES FOR FUTURE REFERENCE To find the values go to Setup gt Line Read gt Setup 4 and write down the values listed there GAIN OFFSET 1 OFFSET 22 TRIP POINT 1 INSTALLATION SECTION A PAGE 39 438 HD SERVICE MANUAL 071 26938 400 TRIP POINT 2 ISSUE 05 01 INSTALLATION SECTION PAGE 40 A 8d Troubleshooting the GBR Line Code Reader White Level Setup Problems If you cannot get proper white level setup values do the following Make sure that the probe lamp is bright If it is not bright follow the instructions in step 3 Move the probe closer to the paper and try again Continue to do this until the probe is nearly touching the paper If this does not work the probe might be broken Normal setting for the probe is 34 from the paper Frequent Misreads Lamp is Bright If frequent misreads are occurring and the probe lamp is bright do the following to section A 8c and make sure that all of your page settings are properly config
69. e Open the folded sheet and place it in front of the roller infeed section 4 Adjust lower dump rollers on exit end of accumulator through hole indicated OWER DUMP ROLLER ADJUSTMENT HOLE 2X Out Of Square Paper If the paper is not cut precisely at right angles the folded sheet may show points By turning a setting screw the fold plate stop can be made parallel to the out of square Note Make this correction only on the first fold plate Correction on combination fold plate UFT 38 It is possible to change the parallelism of the stop by turning the knurled knob 1 Loosen the knurled knob by means of a 4 mm Allen key 2 The angle of the stop is changed by turning the two knurled knobs The stop is parallel to the fold rollers when the two half round marks 3 face each other 438 SERVICE MANUAL ISSUE 05 01 Shadow Fold UFT 38 The lower lip can be adjusted by setting knob 5 Basic position 0 is flush with the top of the knob
70. each group of 48 lines has six bit Write Mask register that allows the user 4 to disable writes on a byte wide basis E 2c Specifications Electrical Bus Interface STD Bus amp CMOS STD Bus compatible VCC 5V 0 014mA 0 090mA SVGA VIDEO CARD GBR Part Number 042 26746 000 E 3a Features e Based on Cirrus Logic GD5420 Super VGA Controller Chip e Industry Standard VGA BIOS e STD BUS Compatible ON BOARD EEPROM stores monitor information 6124513 E 3b General Description The MCM LPM SVGA is a high resolution Super VGA STD 16 Gt BUS video display board that provides low cost standard in m VGA The is based on the Cirrus Logic 005420 LPM MCM 226 1995 Specifications 24681912 T Bus Interface STD 8088 188 Compatible VCC 45v 5 250 with 256K RAM PR cene ne Se Environmental Oe Ri Operating Temperature 0 to 70 C th E Non Condensing Humidity 5 to 95 Configuration e J2 to Touch Screen 438 SERVICE MANUAL ISSUE 05 01 PRINTED WIRING BOARDS SECTION 5 438 SERVICE MANUAL ISSUE 05 01 PRINTED WIRING BOARDS SECTION E PAGE 6 E 4 SERIAL CARD
71. line windowing schemes when interpreting a Line Code The two windowing schemes are High tolerance and Low tolerance reading Having two windowing schemes permits service personnel to select the windowing scheme which is best suited for the customer s application When Low Tolerance read is selected the print line windowing scheme used does not detect paper slippage This means the integrity of the Line Code information must be ensured by the data fields represented within the code A Low Tolerance interpretation of a line code synchronizes the print line windows on the Gate Mark The Print lines following the Gate Mark are divided into absolute locations When a mark is detected it is automatically associated with a Print line number This means the Line Code Recognition System will not look for the standard tolerances applied between Line Code marks When High Tolerance read is selected the print line windowing scheme applies the standard tolerance specification between Line Code marks This makes it likely for paper slippage in the machine to be detected during the interpretation of the Line Code Detecting paper slippage improves the integrity of the Line Code Recognition process It also introduces the possibility of more reading errors being created A High Tolerance interpretation of a line code synchronizes the print line windows on the Gate Mark The Print lines following the Gate Mark are divided into zones of 1 2 print lines Centered
72. number of spaces between the 15 read encoder ticks are being missed To correct this do the following a Check the read encoder belt for smoothness and firmness b Check the main feed belt and the pullout rollers Make sure that the paper is not slipping as it is fed from the feeder into the accumulator e There should be a significant amount of friction between the paper and the main feed belt If there is not much friction there clean the main feed belt citrus cleaner seems to work well on the main feed belt e pullout rollers the rollers that are right after the singulator should be adjusted such that they evenly grip the paper as it moves through Rip off two strips of paper and place the paper on each side of the pullout rollers Turn the rollers by hand and make sure that the two pieces of paper feed through evenly If the paper does not feed through evenly use the adjustments on the sides of the roller shaft to adjust the rollers Lamp is Not Bright If the probe lamp is not bright do the following e Look at the probe in question and determine if it is dim or if there is no light coming from it If it is dim you probably have the wrong probe selected If there is no light coming from the probe the lamp on the reader board is probably burned out Setup gt Line Read gt Setup 4 and set the LAMP value to 255 Look at the lamp on the other probe or where the other probe would have been connected
73. of paper that is most productive to the feeding process The Paper Level Detector monitors the paper through a metal wand Singulator two inch stationary roller which rests above the feed belt in the center of the feeder and allows only the bottom sheet of paper to be fed while holding back all others Feed Sensor The Feed Sensor monitors the output of the singulator for proper singulation or non feed of paper It is a light actuated through beam sensor identified by on the amplifier The sensor module is located on the feeder side frame in the singulator area Double Detect Sensor The Double Detect Sensor monitors the output of the singulator for double feeds It is a light actuated through beam sensor identified by an D on the amplifier The sensor module is located on the feeder side frame in the singulator area Feeder Speed Encoder A blue clad optical encoder located on the right side of the upper pullout shaft It is used to detect feeder run speed 255 DA PER DEMAND PAPER LEVEL SINGULA DETECTOR ROLLER 438 HD SERVICE MANUAL 071 26938 400 ISSUE 05 01 Singulator Figure Feed Clutch Electrical clutch which engages the feed belt at a signal from the controller Read Sensor Reflective beam se
74. of the paper detecting sensors on the 438 are infrared modulated digital sensors Each sensor has it s own amplifier unit and can be adjusted The proper method of adjustment for these sensors is as follows 1 Place a single sheet of paper under the sensor For the Double Detect Sensor place two sheets under the sensor There should be no printing or dark background present on the documents placed under the sensor 2 Adjust the gain potentiometer on the sensor s amplifier unit so the red LED turns off and the green LED remains on Turning the control CCW the sensitivity is lowered and the red light will go out Adjusting the control CW raises the sensitivity and makes the red light get brighter For the Double Detect Sensor the red LED should go off only if two sheets are present 3 Remove the sheet s from under the sensor the red LED should turn on and the green LED stay on If this does not happen readjust the amplifier s gain 438 SERVICE MANUAL ISSUE 05 01 NOTE The green LED on the sensor amplifier is the stability indicating light It indicates that the sensor is adjusted properly The green LED should remain on at all times E O O 17 17 JA a Sensor Figure REPAIR INFORMATION SECTION D PAGE 11 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 12 D 3 REPAIR CHECKOUT PROCEDURES RCP REPAIR CHECKOUT PROCEDURE FOR PAPER COULD NOT BE
75. on the reader card underneath the machine If it is brighter than the probe that you are trying to read with than you probably have the wrong probe selected Go into Setup Line Read Setup 2 and select the other probe Exit out of the setup screens Set up the 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION A PAGE 41 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION A PAGE 42 GBR Line Code Recognition 8051 Board LED Indicators LED1 top Lo to Hi Comparator LED2 Hi to Lo Comparator LED3 Probe B LED4 bottom Probe Test Points T1 Ground T2 5VDC T3 Probe A Preamp T4 Probe B Preamp T5 Lo to Hi Interrupt T6 Hi to Lo Interrupt T7 Read Signal T8 Lo to Hi Comparator T9 Hi to Lo Comparator ol OJ O ol OJ ol ol ol OJ O ol GBR Line Code Board Figure A 8e Physical Specifications of the Line Code System The Print Contrast Ratio should be at least 65 Mark size specifications Minimum length of solid mark 0 3 recommend 5 Minimum width of solid mark 0 015 recommend 020 Maximum width of solid mark 0 030 Clear area specifications 0 064 when using 1 8 line spacing and 0 094 when using 1 6 line spacing minimum clear area between marks taking into account print registration and maximum function line size Clear area required on each side of marks 0 2 Clear area requ
76. paper The lower lip is moved by turning a fine adjustment screw 2 which is equipped with a scale Light paper grades move the lip forward by turning the screw counter clockwise Heavy paper grades move the lip backward by turning the screw clockwise e For difficult to handle paper it is possible to set back the complete fold plate by up to 4 For this two Allen screws 9 have to be loosened at the left and right side of the fold plate A scale 10 facilitates precise setting D 5g Close Fold Plate 38 If the fold plate is not used and must therefore be closed it can stay in the fold unit Setthe fold plate stop to the maximum fold length highest position by turning the setting wheel 1 e Continue turning the adjustment wheel against a slight resistance unit the stop is reached now the deflector is engaged and the fold plate is closed D 5h Setting the Fold Length Fold unit with four fold plates The type of fold determines the position of the fold plates and deflectors The unfolded format determines the fold lengths to be set The fold length is the distance between paper stop and fold line 438 SERVICE MANUAL Type of fold Fold length Fold plate setting DIN A4 DIN A3 210 x 297 297 x 420 1 148 1 210 2 0 2 0 3 0 3 0 Single fold 1 198 1 280 2 99 2 140 Letter 3 0 3 0 fold 4 0 4 0 1 99 1 140 2 100 2 141 Accordion 3 0 3 0 2 f
77. settings must reflect ounces including the inserts and the postal meter itself Likewise if one is set to reflect grams they must all be set to reflect grams The numbers entered are relevant only to each other Postal Meter 1 PM Divert in Inserter Setup 2 is normally set to ON at 200 This will enable the postal meter at the correct time This value may need to be adjusted if the postal meter doesn t place the postage in the correct place Postal Meter 2 found in Inserter Setup 3 should then be set to 40 higher than the new meter 1 value and Postal Meter 3 should be 40 higher than 2 OFF at xx should be set to 10 for all three Station 0 is set to the value of the last chain section of the inserter after the envelope stuffer and the turnover 04 05 06 07 etc this is normally set to 07 on a six station inserter Point xx selects the postal meter output line to the 438 this is normally set to 0 for PM Divert 1 for Postal Meter 2 and 2 for Postal Meter 3 Weight Breaks The 438 will total the weights of all documents inserts and the envelope and then send it to the correct postal meter Because you are setting the weight breaks as well as the envelope page and insert weights it is important to keep the unit of weight i e oz consistent 1 2 Enter the Weight Break of Postal Meter 1 to Postal Meter 2 2 3 Enter the Weight Break of Postal Meter 2 to Postal Meter 3 INSTALLATION SECTION A PAGE 24
78. stainless steel rails mounted on the hopper are adjustable via a locking handle at the rear At the front they interlock with the singulator rails then lock to shafts running across the machine Both sets of rails should be adjusted together A one inch wide yellow timing belt main feed belt drives the bottom sheet of paper under the singulator roller Two red urethane belts are located to either side of the main feed belt These auxiliary feed belts assist the main feed belt smoothing variations in frictional drive correcting erratic feeding of the paper A demand switch monitors the paper going into the feeder area It s job is to limit and demand the amount of paper that is most productive to the feeding process A metal wand monitors the paper level in the singulator area A two inch stationary orange roller rests above the feed belt in the center of the feeder and allows only the bottom sheet of paper to be fed while holding back all others 438 SERVICE MANUAL ISSUE 05 01 A series of sensors monitors the flow of paper through the 438 These are light actuated through beam devices A feed sensor monitors correct singulation or non feed of paper It is identified by an F on the amplifier The double detect sensor identified by an D on amplifier will detect multiple sheets fed from the feeder Other sensors are located in the accumulator section described below On either the left or right feeder side rail is a read sens
79. type is selected Y N Check these points on the cabling to determine where signal is being lost e Check read probe replace as required Check pre amp replace as required e Check read board replace as required Check the wiring to the CPU Repair the wiring as necessary does this correct the problem Y N Check the CPU replace as necessary Code Misread Y N Is the problem corrected by any of the following tests Check read setup again particularly focus Check for correct feed speed Check speed sensor for proper operation N Check for failure on the CPU replace as necessary e Bad UARTs Bad software Check for paper flutter under read head or pullout roller slipping If the waveform is intermittent check the cable connection secure or replace as required 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 21 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 22 Expected End of Group Y N Blank Page Y N N Check the page to determine if error is valid Check GBR read setup Check these points on the circuit to determine where signal is being lost Check read probe replace as required Check pre amp replace as required Check read board replace as required Is the problem corrected by any of the following tests Check read setup again particularly focus Check for correct feed speed Check speed sensor for proper o
80. which vacuum is applied to the envelope hopper Insert Sta is normally set at 2 Envelope Flap Detect is normally set On at 010 Off at 350 and Insert Sta 1 this is the location of the flap detect Ink Mark is an optional device that places an ink mark in varying locations to sort Zip codes visually OFF is the number of chain movements AFTER envelope insertion Ink Marking is normally located at Station 7 Insert Station Vacuum is normally enabled 100 This is the position of the encoder in degrees at which vacuum is applied to the insert station Logical Shift is normally set to On 90 This is used to carry the data with the physical document Bad Package Stop is normally set to On At 80 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION A PAGE 23 438 HD SERVICE MANUAL ISSUE 05 01 071 26938 400 PM Divert Postal Meter 2 and Postal Meter 3 NOTE ON POSTAL METER WEIGHING The 438 can accommodate up to three postal meters PM Divert 2 and 3 are located in Inserter Setup 3 Based on the values entered in Weight Breaks Page Env Wts Ins 1 4 Wts and Ins 5 8 Wts located Inserter Setup 3 the document will be stamped by the appropriate postal meter The dollar value must be manually entered in the postal meter The value you enter in the Postal Meter Weights can be any unit of measure as long as it is consistent If one weight break is set to reflect ounces all other
81. 00 3208 DOCUMENT LOADER page 1 186 035700600 3208 DOCUMENT LOADER page 1 INDEX PART NUMBER 1 2 3 gt SMART FEEDER SERVICE MANUAL 4 005 039 1 027 444 1 027 441 4 005 081 1 027 411 1 007107 4 005 080 1 027 411 1 007 107 4 005 022 1 155 587 4 005 022 1 114 001 4 005 036 DESCRIPTION COVER COMPLETE HINGE HAND WHEEL LEFT GUIDE RAIL COMPLETE KNURLED SCREW LEAF SPRING RIGHT GUIDE RAIL COMPLETE KNURLED SCREW LEAF SPRING HOLD DOWN COMPLETE KNURLED SCREW HOLD DOWN COMPLETE KNURLED SCREW STOP ROLLER ISSUE 05 01 PARTS SECTION I PAGE 67 SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 68 186 035700600 3208 DOCUMENT LOADER page 2 186 035700600 3208 DOCUMENT LOADER page 2 INDEX PART NUMBER DESCRIPTION 1 4 004 539 BEARING 2 4 004 539 BEARING 3 4 004 539 BEARING 4 4 005 028 PULLEY 5 1 033 006 BELT 6 4 005 025 PULLEY 7 2 022 456 PLATE SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 69 SMART FEEDER SERVICE MANUAL ISSUE 05 01 186 035700600 3208 DOCUMENT LOADER page 3 ars 2211 5 1 PARTS SECTION I PAGE 70 186 035700600 3208 DOCUMENT LOADER page 3 INDEX PART NUMBER DESCRIPTION 1 1 029 244 SWITCH 2 1 029 244 SWITCH 3 1 033 005 BELT 4 1 027 446 PULLEY 5 1 027 446 PULLEY 6 1 027 445 PULLEY 7 4 005 049 ROLLER SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS
82. 01 ZZ DIN 625 1027430 2041183 4005232 2x 1150012 4x 4x6 DIN 6325 1110023 24x1 2 DIN 472 438 SERVICE MANUAL 071 26938 400 1143006 1122003 2x 5 934 4005225 4005230 1143006 2 5 16 DIN 912 1107003 2x A5 3 DIN 125 1003037 2 2036334 2036248 02 01 SECTION J 9 CLUTCH BRAKE 1030284 2012751 2901559 1103019 2012999 3 5 84 1030342 1107001 200147 4 8 4 DIN 125 1122002 2017501 8 DIN 934 1030285 2001472 2011619 1112030 2 1030343 6900 77 DIN 625 1030344 1110030 2x 22x1 DIN 472 438 SERVICE MANUAL 02 01 071 26938 400 SECTION J 10 BALL BEARING EJECTOR SHAFTS 2001599 1056001 1143006 2022429 1170006 4004390 1170006 2022429 438 SERVICE MANUAL 02 01 SECTION J 071 26938 400 11 FLAT BELT DRIVE LEFT INPUT SIDE Zahnriemen 200XL 037 belt 200XL 037 2023064 2001697 4 y E YSN lt AYRA RS ne ee ar ta 2001390 NEN N KA SOR N FE 2021143 438 SERVICE MANUAL 02 01 SECTION J 071 26938 400 12 ACCUMULATOR PARTSLIST Part Description Oty 1001014 EXTENSION SPRING 3 1003037 COMPRESSION
83. 031625 BRACKET 2 2031626 2 2031636 RAIL RIGHT 1 2031637 RAIL LEFT 1 4006937 BELT TENSIONER 1 4006688 TRANSPORT ROLLER 4 2023434 PLATE 2 1029206 TERMINAL STRIP 1 2021092 WASHER 4 2021238 WASHER 2 2021269 WASHER 1 2021534 WASHER 2 2021984 WASHER 2 2022503 WASHER 5 1110008 10X1 SAFETY CLIP 2 1110023 24 1 2 SAFETY CLIP 5 1133010 SAFETY CLIP 2 1150010 6 10 DOWEL 1 1150018 M6X12 DOWEL 2 1191013 16X22X0 2 SHIM 1 1192001 WASHER 1 1192002 5 5X18X1 6 WASHER 1 1150005 x 14 DOWEL 4 1150011 6 20 DOWEL 4 438 SERVICE MANUAL 02 01 071 26938 400 SECTION J 16 SECTION MB FOLDER 186 034007658 MB FOLDER PAGE 1 186 034007658 MB FOLDER PAGE 2 186 03400765B MB FOLDER PAGE 3 186 03400765B MB FOLDER PARTS LIST 186 034007658 FOLDER page 1 186 034007658 MB FOLDER page 2 186 034007658 FOLDER page 3 186 034007658 FOLDER PARTS LIST INDEX PART NUMBER 2 070 145 2 070 144 2 017 391 1 017 631 1 017 640 1 017 644 1 017 642 1 017 639 1 017 635 1 017 636 1 017 641 1 017 643 2 017 373 4 004 629 3 504 014 1 033 026 1 031 072 2 017 413 2 017 414 2 017 415 2 017 416 2 017 418 2 017 417 2 017 375 4 004 612 2 006 510 2 001 148 2 022 298 1 001 139 1 001 140 1 017 496 1 059 029 2 006 511 2 029 451 DESCRIPTION COVER LEFT COVER RIGHT ROLLER POLY STEEL INDICATOR SETTING KNOB A SETTING KNOB 4 SETTIN
84. 033063 2 4005227 1110013 9x1 DIN 471 006617 1107001 DIN 125 1143018 10330053 OIN 912 2030854 2036137 2x 1059028 12x 2013174 nit 3509015 2017499 2013014 8x 3504014 8x SECTION J 2 INPUT SIDE VIEW 90 7 99220 0877204 SZOZLLL 9 557002 668060 707056 2544402 0602 509402 8971002 200 7 997100 SLOOOSE 7LVELOZ E6ELOOZ ezoeso 1819802 NA 7 HE 5 RR iI SO0EEOL 6LOEFLL LOOZOLL 499002 0052204 SSSZLOL ELOOLLL 2042202 ESOEEOL 4226007 9225007 709 502 SECTION J 02 01 438 SERVICE MANUAL 071 26938 400 3 EJECTOR SIDE VIEW S6OEEOL 9671102 600 IL LI ems 6LOE YUL Ks S 100201 899002 27120 ELOOLLL 6225007 an i er a SNEEOL erozii EN Bar 1111 KH Lu ol 467002 9471002 u H u f f 00 74 267 002 20070 4 SI ER 216 8XGW 8XSW LLOE7LL XE LLOEFLL 21980602 04976202 9980 02 SECTION J 02 01 438 SERVICE MANUAL 071 26938 400 4 INPUT SIDE VIEW 7176202 XZ 6971002 78 8XGW 7 EOSZLOZ SOSZLOZ 6971002 Eli o sa ur cu
85. 05 032 25565 000 032 26794 000 033 26786 000 049 26784 500 067 26722 500 194 26798 600 186 034007109 DESCRIPTION END STOP GROUND TERM BLOCK BASE TERM BLOCK END COVER THROUGH TERM BLOCK END PLATE ADJACENT JUMPER FERRULE 16 AWG FERRULE 22 AWG OUTPUT MODULE RELAY 3 PDT 11 PIN SOCKET RELAY 11 POS FUSE 8 AMP FUSE 63 AMP FUSE PLUG MOTOR SPEED CONTROL VARISTOR DIN RAIL FOLDER MB ISSUE 05 01 PARTS SECTION I PAGE 43 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 44 750 26525 500 WIDE TRANSPORT CONVEYOR page 1 750 26525 500 WIDE TRANSPORT CONVEYOR page 1 INDEX PART NUMBER oNOOPOD 10 11 12 13 15 16 17 18 19 20 438 SERVICE MANUAL 002A 18044 002B 08408 002B 08413 002B 08445 002B 08457 002 08463 002 08486 002 08487 600 19011 002 19599 002 08409 600 18635 002 18717 020 HS31020830 020 RA025C0803 020 RA025C0806 112 200DOA25637 112 S6A320NF037 113 200180037 113 200220037 113 200230037 144 26309 600 169 26538 600 DESCRIPTION PULLEY ASSEMBLY BRAKE MAGNETIC EXTENSION ASM INTERLOCK ASSEMBLY SENSOR MOUNT ASSEMBLY SENSOR MOUNT ASSEMBLY DISCHARGE SENSOR PACKAGE PRESSURE SENSOR MOUNT BRACKET CLUTCH SHAFT ASSEMBLY CLUTCH ONLY SHAFT ONLY CONVEYOR COVER ASM S
86. 071 26938 400 ISSUE 05 01 Inserter Setup 1 Ins Stations 4 6 4 4 6 4 4 6 Choose Inserter configuration Open Stations Select 0 for GRIPPER 1 4 for Open feed e Normally set to GRIPPER Inserter takes the folded document from the 438 e Select OPEN FEED when the 438 will be placing the folded documents directly on the inserter track When using open feed selected number represents the number of stations prior to the first insert station the package was placed Encoder Type e 100 Tick or 36 Tick Logic Type INSTALLATION SECTION PAGE 21 438 HD SERVICE MANUAL 071 26938 400 775 420 438 control of 775 Inserter functions station Select Envelope Disable Envelope Detect Disable InkMark Divert Postal Meters e AC DC 420 438 control of non 775 Inserter functions station Select Envelope Disable Envelope Flap Detect Disable InkMark Divert Postal Meters e Station Setup 1 4 e Station Setup 5 8 Station Setup Note Insert Station positions are referenced from the station at which the documents are inserted into the envelope Insert Sta 0 Insert Station 1 would be the station downstream from Insert Station 0 Insert Station 1 is the Insert Station upstream from Insert Sta 0 ISSUE 05 01 INSTALLATION SECTION A PAGE 22 Inserter Setup 2 1 Envelope Station Vacuum is enabled at 230 This is the position of the encoder degrees at
87. 16122 033 600B 16404 005 600B 16430 600B 17312 600 17541 600 17848 095 27252 500 6000 22275 LEFT FEEDER CHASSIS RIGHT FEEDER CHASSIS RIGHT PAPER GUIDE RAIL LEFT PAPER GUIDE RAIL SHAFT DRIVE PULLEY PULLEY MOUNTING BLOCK HANGER GUIDE RAIL TENSIONER SHAFT TIE BAR RAIL GUIDE PULLEY FEED DRIVE TIE PLATE HOPPER FEED SHAFT HUB ROLLER BEARING DRIVE ROLLER FEEDER MOUNT BAR PULLOUT ROLLER UPPER PULLOUT SHAFT SHAFT SINGULATOR DRIVE FEEDER TRAY PARTS SECTION I PAGE 13 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 14 549 26603 500 FEEDER ASSEMBLY page 2 549 26603 500 FEEDER ASSEMBLY page 2 INDEX PART NUMBER 1 002A 16437 2 002A 16457
88. 29 Eme Read Setup ii na es lentes 29 Line Read Setup 2 eerte prre RE nter te 32 Line Read Setup 3 noi 36 Line Read Setup 4 se essen ses 39 A 8d Troubleshooting the GBR Line Code Reader 40 White Level Setup Problems 40 Frequent Misreads Lamp is 40 Lamps 41 A 8e Physical Specifications of the Line Code System 43 Code location on 43 A 9 LASER BAR CODE READ OPTION entente tnn 44 Ada LaserSafety uei er Wed A 44 Bar Code Basics uie ARR ES HIE 45 A 9c Adjusting Your Model 30 Scanner see 45 A 9d Setting 438 to Read Laser Bar 46 Bar Read Setup 15 cette ce ere f t e nn 47 INTRODUCTION SECTION A PAGE 1 438 HD SERVICE MANUAL 071 26938 400 A 1 REQUIRED MANUALS The following manuals are available for the 438 071 26552 400 MB MULTIMASTER 38 OPERATOR 2 INTRODUCTION TO THE MANUAL This manual is intended for service technicians and is organized to enhance maintenance troubleshooting and repair of the 438 Installation of the 438 is also described INTRODUCTION THE MACHINE A 3a FEEDER SECTION 4385 feeder is bottom fed top loading for continuous operation with capacity of 1500 sheets 20 Ibs Creeper Conveyor The Creeper convey
89. 3 20 600B 19961 21 600B 21843 22 600B 22478 23 XXXX 24 600C 19041 25 600C 19439 26 600C 19439 27 600C 21842 28 600C 22436 29 526 26846 500 30 600D 22366 438 SERVICE MANUAL DESCRIPTION CABLE FEEDER BOX LEVELING MOUNT POWER BOX CONTROL PANEL CABINET SUPPORT FINGER GUARD SWITCH ADAPTOR PLATE LOCK WITH KEY CABLE ON OFF POWER SWITCH CABLE ON OFF POWER SWITCH CABLE ON OFF POWER SWITCH LOCATING PIN TUNNEL ANCHOR GROUND SCREW LEVELER SUPPORT BLOCK CABINET PANEL ANGLE MIDDLE TIE BAR MESH SCREEN INFEED PLATE XXXX SWIVEL CASTER SUPPORT TOWER SUPPORT TOWER FRONT COVER JACK SUPPORT CABLE DOUBLE DETECT EXT CABINET PANEL ISSUE 05 01 PARTS SECTION I PAGE 5 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 6 580 27508 500 CONTROL PANEL ASSEMBLY
90. 39 27431 000 039 27435 000 041 25066 041 26521 500 045 014130 046 0140581 062 2174395 514 26146 000 526 26700 501 526 26700 502 584 27325 600 584 27429 600 025 B398VN 045 014135 DESCRIPTION TERMINAL BLOCK NEUTRAL INSERTION BRIDGE Q DIS FEMALE 16 14 GA CABLE GLAND 15 5mm DUMMV MODULE FUSE 10A 600V FUSE 15A 600V CONNECTOR FRAME 10 HOOD HOUSING CONN PANEL FRAME MOUNT HOOD CONTAGT INSERT MALE CONTACT INSERT FEMALE SOCKET CONTACT 14 14 GA ROCKER SWITCH DISCONNECT SWITCH ASSEMBLY WIRE 14 GA BLACK CABLE 5 COND 14 GA TRANSFORMER CONTACT SPRING CRIMP POWER SWITCH CABLE POWER SWITCH CABLE INFEED PLATE TRANSFORMER PLATE RING LUG 8 14 16 GA WIRE 14 GA GREEN ISSUE 05 01 SECTION I PAGE 86 389 27146 400 5 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 87 438 SERVICE MANUAL 389 27146 400 BUHRS INTERFACE KIT OPTIONAL INDEX PART NUMBER 5 0 002 08461 007 27149 600 014 04021106
91. 4 Calibration Procedure FOR 1 10 1 8 AND 1 6 SPACED LINE CODES 1 Check all mechanical setups in the machine Examples e Friction feeder is free of mechanical binding e Singulator is adjusted properly e Documents are processed through machine without distorting the paper e All paper hold downs are set up properly e Paper rails are set to the proper width 2 Line Read Setup 4 and all preceding Setup 2 must be performed first 3 Select Calibration On 4 Press 5 Now feed a single Calibration document on the machine 6 If none of the following errors are declared when a calibration document is fed the Line Code Recognition system is calibrated for the current selected Line Code spacing Errors Indicating A Bad Calibration e NOFEED GATE MARK DETECTED GATE MARK DETECTED IN 2ND BANK e CALIBRATION OUT OF RANGE 7 Ifa bad calibration is indicated RECALIBRATE must be selected before another Calibration document is fed Go back to step 4 Tolerance Use LOW setting unless there is not a good contrast between the document background and the function marks The LOW setting will tolerate some drift in the printer registration Use of the HIGH setting does not allow drift in the printer registration The mark location is very critical if the HIGH setting is used Use it if the contrast between the document and the function marks is poor The Line Code Recognition system supports two print
92. 4 500 SINGLE CHANNEL DOUBLE PROBE READ INDEX PART NUMBER DESCRIPTION 1 002B 08063 DUAL PROBE OUTPUT CABLE 2 002B 08126 DUAL READ ENCODER CABLE 3 002B 08407 LINE CODE SENSOR 4 002B 18518 ENCODER ASSEMBLY 5 002B 19353 BLOCK READER 6 002C 08013 S CHANNEL DUAL PROBE PLATE 186 330002717 SENSOR AMP BOARD ONLY 7 002C 08104 OMR FIBER SENSOR 8 007 26389 600 BRACKET 9 024 26390 600 DIN RAIL 10 026 450937372C SPRING CLIP 11 026 ABMMA TIE WRAP ANCHOR 026 PLT1MM WRAP 12 039 39000041 18 24 039 39013023 PLUG MINI 2 POS 13 042 26908 500 SINGLE CHANNEL READ BOARD 14 047 27782 500 RESISTOR ASSEMBLY 15 057 FT500 SENSOR FIBER 16 140 02500170E2 TUBING 25 17 144 27687 500 PAPER GUIDE ASSEMBLY 18 186 330525774 SENSOR SCANNER 19 526 27685 500 SPLITTER CABLE 20 600A 18374 PULLEY 21 600A 18378 BELT 22 600A 19261 SENSOR MOUNT 23 600B 19306 BOTTOM PROBE MOUNT 24 600B 19307 TOP PROBE MOUNT 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 61 SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 62 002K 08432 INSERTER DEMAND SWITCH KIT 002 08432 INSERTER DEMAND SWITCH INDEX PART NUMBER 1 our WP 438 SERVICE MANUAL 002B 08460 041 35701 600B 18138 002B 08461 600B 18139 600B 18161 DESCRIPTION DEMAND SWITCH INTERCONNECT CABLE INTERLOCK MAGNET MAGNETIC CAM BLOCK DEMAND BLOCK
93. 40Mhz X 2 full PC AT hardware complement and industry standard on a 1 486DX2 with 32 Mb DRAM AWARD BIOS assures full hardware and software VCC1 12V 5 Not required PC 104 or compatibility with PC software and operation systems The Cooling Fan Use Only includes onboard interfaces for floppy disks IDE VCC2 12 5 Not required PC 104 Use only fixed disks parallel printer and two serial channels with RS 232 RS 422 or RS 485 capability on either or both channels A full 16 Bit PC 104 expansion BUS is provided in addition to the STD Bus interface for further expansion to an entire industry of add on peripherals including high speed Addressing 64 Mb addressing 32Meg max onboard BIOS ROM Socket 128Kb EPROM DRAM Memory 16 SMT J lead locations on both sides of the board supporting factory configurations form1M to 32 Meg SSD Memory One 32 pin JEDEC Standard socket supporting 4 Mb SRAM 4 Mb PEROM 4 Mb EPROM 16 Mb EPROM or the M Systems DOC Module Environmental Operating 40 to 70 a i Non Condensing Humidity 5 to 95 X UI E 1d Configuration 28 ue Jumpers as shown diagram J1 to touch screen J1 to RS232 connector on cabinet
94. 438 to be used in a stand alone configuration Transfer Conveyor 8 5 and 11 versions Transfer Conveyor Package Presence Sensor and Module This monitors the presence of paper packages in the first station of the transfer conveyor Transfer Conveyor Discharge Sensor and Module This monitors the discharge of paper packages from the output conveyor acts to confirm the processing of specific documents LL A 3f EMERGENCY STOP INTERLOCKS The main E stop located on the operator panel will interrupt power to the conveyors and folder when pressed down This switch must be twisted to bring it back to it s original upper position An extra contact is provided on this E stop switch which is routed to pins 30 and 33 of the Inserter Connector located on the adaptor plate on the end of the cabinet This will effect an E stop to an external device when these contacts are wired to the E stop circuit on that external device e g Pinnacle A connection to the 438 interlock string has been provided on pins 28 and 29 of the same Inserter Connector which allows an external device e g Pinnacle to E stop the 438 For this E stop string to be functional a blue jumper across pins 24 and 25 of Module 7 on the I O Board must be removed If this E stop string is not used this jumper must be in place Pin 11 of this connector also provides an Interlock Sense signal to an external device There are six 6 safety interlock switches which wi
95. 50 26558 500 NARROW TRANSPORT CONVEYOR page 1 INDEX PART NUMBER 00 40 11 12 13 14 15 16 17 18 19 20 21 22 002 18044 002 08408 002 08413 002 08445 002 08457 002 08463 002 08486 002 08487 002 19599 002 08409 600 18635 002 18243 020 531020830 020 RA025C0803 020 RA025C0806 112 200DOA25637 112 S6A320H3712 113 200180037 113 200220037 113 200230037 144 26309 600 169 26538 600 526 26327 500 579 26407 500 DESCRIPTION PULLEY ASSEMBLY BRAKE MAGNETIC EXTENSION ASM INTERLOCK ASSEMBLY SENSOR MOUNT ASSEMBLY SENSOR MOUNT ASSEMBLY DISCHARGE SENSOR PACKAGE PRESSURE SENSOR CLUTCH SHAFT ASSEMBLY CLUTCH ONLY SHAFT ONLY CONVEYOR COVER ASM STANDOFF 10 32 1 875LG SPACER 25CL 187LG SPACER 25CL 375LG TIMING PULLEY 25T TIMING PULLEY 20T TIMING BELT 18PL TIMING BELT 22PL TIMING BELT 23PL INFEED GUIDE TIE BAR HANDLE TRANSPORT CABLE COVER 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 579 26535 600 584 26516 600 600 17700 6004 17735 6004 17785 584 26310 600 6008 18108 6008 18109 6008 18639 6008 18640 6008 18644 6008 17693 006 26550 600 006 26554 600 6006 18716 6000 17724 6000 18035 6006 18140 600 16349 034 600 16349 027 SHIELD RIGHT CONVEYOR SUPPORT DRIVE PULLEY RIGHT PIVOT STOP LEFT PIVOT STOP INFEED GUIDE RIGHT HINGE LEFT HINGE SHAFT SHAFT DRIVE SHAFT SHAFT RIGHT CONVEYOR RAIL
96. 5003 15820 SECTION PAGE 14 Jam At Out Sensor Error EVENT INSERTER Xcvy Clutch ON to Pack into Xcvy Out Sensor EVENT CHECK JamAtOutTimer CHECK VALUE 3000 msec ADJUST VALUE Engin Value 22 ANALYSIS Time exceeded Jam At In Sensor Error EVENT HOPPERFILL Xcvy Clutch ON to Pack into Xcvy Sta 1 In Sensor EVENT CHECK JamAtinTimer CHECK VALUE 500 msec ADJUST VALUE Engin Value 23 ANALYSIS Time exceeded At Out Sensor Error EVENT HOPPERFILL Pack into Xcvy Sta 1 In Sensor to Pack into Xcvy Out Sensor EVENT CHECK JamAtOutTimer CHECK VALUE 3000 msec ADJUST VALUE Engin Value 22 ANALYSIS Time exceeded Jam Into Xfer Cnvy Station 1 EVENT HOPPERFILL Xcvy Clutch ON to Pack into Xcvy Sta 1 In Sensor EVENT CHECK IntoStation1Timer CHECK VALUE 225 msec VALUE 100 Speed ADJUST VALUE Engin Value 8 ANALYSIS Time exceeded 15821 Jam Out Of Xfer Cnvy Station 1 EVENT HOPPERFILL Xcvy Clutch ON to Pack out of Xcvy Sta 1 Sensor EVENT CHECK OutOfStation1 Timer CHECK VALUE 60 msec VALUE 100 Speed ADJUST VALUE Engin Value 9 ANALYSIS Time exceeded C 3f 16xxx or 18xxx Reader nn 16 Bar Read Messages or nn 18 Line Read Messages Error Description nn001 GROUP NUMBER OUT OF SEQUENCE nn002 EXPECTED END OF GROUP nn003 BLANK PAGE 438 SERVICE MANUAL Cause Remedy The page that was just fed did not follow t
97. AGE 77 SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 78 750 26978 500 3208 FEEDER MECH INTERFACE SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 79 SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 80 750 26978 500 3208 FEEDER MECH INTERFACE INDEX PART NUMBER DESCRIPTION 1 002A 16457 004 THUMBSCREW 8 32 X 375 2 002A 16495 003 THUMBSCREW 6 32 X 25 3 002A 16496 005 THUMBSCREW 10 32 X 5 4 007 26955 600 BRACKET DOCKING 5 007 26956 600 PLATE DOCKING 6 013 2104 NUT NYLOCK 0 24 7 014 31031308 BOLT SHOULDER 312 X 5 8 018 26958 600 PIN DOCKING 9 020 26957 600 SPACER DOCKING 10 108 26979 600 LINK MOD 11 144 26981 600 PLASTIC STRIP 12 186 035700675 BULK LOADER 13 584 26980 600 PLATE 14 600A 19367 MOUNT BLOCK 15 600A 23340 CLAMP BRACKET 16 600A 23485 MYLAR STRIP 17 600B 18872 LEFT GUIDE RAIL 18 600B 18873 R
98. B 07742 002C 07627 002D 08522 001 002D 08522 003 002D 08522 004 002B 08662 024 1401019 030 1240025 032 003 8250 032 10120250 047 59841 050 20VDK1 054 125 DESCRIPTION CABLE 1 INT CABLE AC CORD SENSOR amp SIGNAL CABLE CREEPER CABLE MAIN MOTOR CABLE SPEED CONTROL POT TERMINAL BLOCK SOLID STATE RELAY FUSE 3 8 FUSE 12 RESISTOR LINE FILTER MOTOR CONTROLLER ISSUE 05 01 PARTS SECTION I PAGE 25 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 26 002D 17505 CREEPER CONVEYOR 0020 17505 CONVEYOR INDEX PART NUMBER oNOOPOD 438 SERVICE MANUAL 002B 09341 002B 16631 002B 16633 002B 16334 016 525 112 200DBA 15625 113 200500037 113 200070037 126 55 25 172 1039 1032 600 15841 009 600 15841 011 600 15841 015 600 15841 017 600 15841 020 600 15841 021 112 200 14638 600 16651 600 16652 600 15841 014 600 15841 019 600 15917 005 600 15841 001 600 16575 001 600 16575 002 600 17771 DESCRIPTION CREEPER MOTOR FRONT S
99. BIK 13 BRN BLK 1 ORN IK d AK AN uum ABE BLK 881 NOTE 1 ALL WR CONTRO N 17 05 a RI BK OA y BIK 75 T BPS P Dk 12 8 S 5 9 gt 2 RED 1 2 XI 3 9 lt gt gt ja NWT g PE us SS e CRN PE GN XI PE lt 73 4 74 15 SI U YS 5 gt NO 28 2 ali 79 USED lt L vat e Bass da 80 X4 i 10 33 43 70 X4 PE xD E 71 X5 PE 2 2 10 ze 82 5 SED ES 1 0 S 125 2 C P 8 1 L LINE 11 PE L LOAD em m e e kI kw A LENZE 9 8 KM 39 4 PE 6 UG 6 E1 E2 E PE U N 20 28 S Gc 7 00 0 B e e amp amp Ss gt gt n 5 S g 5 So c a Y lt pe us Se Nes M 17 gt
100. CE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 1 438 SERVICE MANUAL 0 1 INITIAL 5 Initial Actions used to gather information from the operator concerning problems in 438 Procedure Ask the operator to describe or demonstrate the problem Request all information on the failure If there is an error message refer to the index for guidance to appropriate RCP Some features of the machine may not be tested during the system checks and therefore operator input will be a valuable asset to help diagnose the total system If the problem is the result of improper operator action refer the operator to the operator documentation or instruct the operator on the proper actions Switch the 438 AC power OFF Check all areas of the machine for paper or other obstructions including inside the Folder Remove any paper or obstructions Feed a sheet through the machine to confirm that alignment adjustments are correct ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 2 Turn ON the 438 press RESET ON and confirm the following e All drive belts are moving e Sensors are not blocked or fouled Machine operating parameters set correctly Document inserted in paper hopper passes through and is properly folded NOTE If physical paper jams recur and mechanical adjustments are correct escalate service Potential trouble spots are numerous but include worn or damaged parts stretched
101. CHOR TY WRAP MODULE RED MODULE WHITE I O BOARD PB24 SM WIRE 18 AWG GREEN WIRE 22 AWG GREEN WIRE 22 AWG BUSS CABLE RIBBON 28GA 50 COND CAPACITOR 47uf 35V RUBBER MOUNT 8 CABLE TERMINAL BLOCK OPTO RACK BAR PANEL ISSUE 05 01 PARTS SECTION I PAGE 7 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 8 002D 08135 POWER UNIT A C BOX
102. ENT AXLE HEX NUT STACK SWITCH ACTUATOR SINGULATOR ROLLER ROLLER GUARD ADJUSTING FORK ADJUSTING PLATE ADJUSTING KNOB ISSUE 05 01 PARTS SECTION I PAGE 21 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 22 002B 21905 OUTSIDE FEED BELTS 0028 21905 OUTSIDE FEED BELTS INDEX PART NUMBER DESCRIPTION 1 002B 21906 HOUSING ASSEMBLY 2 002A 21927 ROLLER ASSEMBLY 3 600 22189 IDLER ROLLER 4 186 2823500088 TRACTOR 118 30307 600 5 600A 20965 PULLEY 6 600A 21908 BUSHING 7 600A 21909 AXLE 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 23 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 24 002D 08522 FEEDER ELECTRICAL ASSEMBLY LE 1 0020 08522 FEEDER ELECTRICAL ASSEMBLY INDEX PART NUMBER 00 4 09 438 SERVICE MANUAL 002B 07741 002
103. FACE 044 27423 400 EUROPEAN POWER CONVERSION SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 85 SMART FEEDER SERVICE MANUAL 044 27423 400 EUROPEAN POWER CONVERSION INDEX PART NUMBER 5 0 024 25384 000 024 26017 000 025 53125 026 27430 000 026 27434 000 032 26752 000 032 26753 000 035 27424 000 035 27425 000 035 27426 000 035 27427 000 035 27432 000 035 27433 000 0
104. G KNOB 2 SETTING KNOB E LOCK WASHER WASHER SETTING KNOB 1 SETTING KNOB 3 SHAFT ROLLER SET SCREW POLYFLEX V BELT FLAT BELT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT LEVER RIGHT BOLT BUSHING WASHER EXTENSION SPRING EXTENSION SPRING GEAR TEFLON BEARING STUD SLIDE 4 004 616 2 006 506 4 004 401 2 006 508 1 200 005 4 006 272 4 004 614 4 004 615 4 004 618 4 004 617 4 004 621 4 004 619 4 004 630 1 133 006 4 004 620 2 027 940 2 022 297 1 112 013 4 006 424 1 030 147 4 004 613 2 029 042 4 006 075 1 003 089 1 191 021 2 029 041 4 007 914 4 007 916 4 007 915 PLATE RIGHT STUD ENCODER DISK STUD ALLEN SCREW BELT TENSIONER LEVER LEVER PLATE RIGHT w L HAND THREAD PLATE LEFT PLATE LEFT w L HAND THREAD PLATE LEFT w L HAND THREAD PULLEY C CLIP PLATE RIGHT w L HAND THREAD SLIDE WASHER BALL BEARING PHOTODETECTOR MOTOR LEVER LEFT GUIDE RAIL HAND WHEEL COMPRESSION SPRING SHIM PLATE FOLD PLATE 1 FOLD PLATE2 amp 4 FOLD PLATE 3
105. GBR Part Number 042 27623 500 E 4a Function e Provides additional serial communications Used with Bar Code Read E 4b Configuration e Jumpers as shown diagram J1 to Bar Code Reader R4 2 4 310 Wt RT af gt 5 110 ie a d R12 c 5J 247 iz RAS RIS 2 RI dE RI6 5 2 ARIS RM 45 RIS LRO li ka 871 v 1 56 RAT 5 SINGLE CHANNEL READ CARD GBR Part Number w GBR Line Code 042 25272 500 GBR Part Number w B H Line Code 042 26908 500 E 5a Function e Interfaces with the BUS Processes signals from the GBR TJ or B H Line Code Cards Processes Read Tachometer signal For B H Line Read process edge detect and bar detect
106. HAFT ASSEMBLY MOTOR MOUNT PLATE RIGHT MOTOR MOUNT PLATE LEFT WAVY WASHER MOTOR DRIVE PULLEY CONVEYOR BELT DRIVE BELT SET SCREW COLLAR HANDLE DRIVE SHAFT SHAFT STACK GUIDE LOCK ECCENTRIC IDLER ROLLER SHAFT BRACKET HANDLE IDLER STUD PULLEY TIMING 14T ROLLER ROLLER TENSION BAR LOCK ANGLE MYLAR COVER BED STACK GUIDE LEFT STACK GUIDE RIGHT REAR CREEPER COVER ISSUE 05 01 PARTS SECTION I PAGE 27 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 28 580 26544 500 KEYBOARD ASSEMBLY 580 26544 500 KEYBOARD ASSEMBLY INDEX PART NUMBER DESCRIPTION 1 041 E22JLB2N8 E STOP SWITCH 2 041 E22B1 CONTACT BLOCK 3 580 26331 600 PANEL 4 041 ATHO1982GRN GREEN LENS CAP 5 041 ATHO1982CLR CLEAR LENS 6 041 ATHO1982YEL YELLOW LENS CAP 7 002B 08542 KEYBOARD CABLE 8 041 OTH36F220 SWITCH 9 041 ATH25F1 SWITCH ELEMENT 10 600B 20846 KEY FOB 11 046 26204 500 CABLE HOST E STOP 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 29 438 SERVICE MANUAL I
107. IGHT GUIDE RAIL 19 600D 20963 SINGULATOR COVER 750 27737 500 3208 FEEDER ELECT INTERFACE page 1 Al Mm E 0000 ji SMART FEEDER SERVICE MANUAL t T 16 KA ISSUE 05 01 5 SECTION I PAGE 81 I x D E o TIN N T7 NES NC SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 82 750 27737 500 3208 FEEDER ELEC
108. ING PULLEY 20T TIMING PULLEY 20T SET SCREW COLLAR BEARING 375ID 50D RADIAL BEARING TRANSPORT CABLE PLATE CLAMP COLLAR SPUR GEAR HUB CLAMP DRIVE ROLLER BEARING DRIVE PULLEY COLLAR RIGHT PIVOT STOP 27 28 29 30 31 32 33 34 35 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 6004 17742 6004 17785 600 18200 600 18568 6008 17689 6008 17743 6008 17744 6008 17745 6008 17746 6008 17747 6008 17888 6008 18165 6008 18639 6008 18640 6008 18642 6008 18643 6008 18644 6008 18645 6008 18646 169 26556 600 6008 18648 6008 18649 6008 18650 6008 19304 6008 19305 177 27369 500 UPPER ROUND BELT LEFT PIVOT STOP CLUTCH STOP MOUNT BLOCK NIP ROLLER IDLER LOWER ROUND BELT UPPER IDLER BELT LOWER DRIVE BELT LOWER EXIT BELT UPPER EXIT BELT PAPER GUIDE TRANSPORT WIRE GUARD SHAFT SHAFT DRIVE SHAFT SHAFT DRIVE SHAFT NIP WHEEL PIVOT BAR TIE BAR SUPPORT BAR IDLER SHAFT SHAFT UPPER DRIVE SHAFT UPPER EXIT GUIDE LOWER EXIT GUIDE IDLER ROLLER 750 26558 500 NARROW TRANSPORT CONVEYOR page 1 gt p 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 49 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 50 7
109. INTERLOCK SWITCH PIVOT MOUNT SWITCH BRACKET ISSUE 05 01 PARTS SECTION I PAGE 63 SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 64 709 26907 500 TOUCHSCREEN ASSEMBLY eder come TA a 24 pd x 7 ES 1 UI e 2 N 4 1 3 p Qu 9 Bn P ay 8 1 1 1 4 EN i KI AE 9 Y pi 4 og OG 221 de Dm SECTION A
110. IS Interlock ON at machine powered 11824 Exit Sensor Error EVENT Exit Demand EVENT CHECK Exit Demand and Exit Sense Inserter Station 1 Sense CHECK VALUE ADJUST VALUE ANALYSIIS Inserter Station 1 Sense covered for 6 demands Sensor blocked 438 SERVICE MANUAL ISSUE 05 01 PROBLEM ANALYSIS SECTION C PAGE 9 438 SERVICE MANUAL ISSUE 05 01 PROBLEM ANALYSIS SECTION PAGE 10 C 3b 12xxx Feeder Error Description 12001 No Feed Error EVENT Feed Clutch ON page lead edge to Feed Sensor EVENT CHECK NoFeedTimer CHECK VALUE 500 msec ADJUST VALUE ANALYSIS Time exceeded 12820 DOUBLE PAGE FED EVENT Under Feed Sensor Double Detect Sensor EVENT CHECK DoubleDetectCount CHECK VALUE gt 2 ADJUST VALUE ANALYSIS DoubleDetectCount exceeds 2 12821 MISSED PAGE EVENT Page lead edge to Feed Sensor next page lead edge to Feed Sensor EVENT CHECK Page lead edge to Feed Sensor CHECK VALUE ADJUST VALUE ANALYSIS e page trail edge Trail of previous page sensed e This error can be caused by electronic noise generated by the 438 or a connected machine INITIAL ACTION Ground the 438 and the connected machine i e inserter together Plug the Open Feed Sensor into the Transfer Conveyor Exit Sensor Plug if using this option f 438 is not in a read mode go to Setup gt gt Feeder gt gt Pulse Feed and make sure None is not selected Obtain GBR T
111. LEFT SUPPORT RAIL SHIELD LEFT CONVEYOR SIDE PLATE RIGHT CONVEYOR SIDE PLATE SHIELD HUB CLAMP SPUR GEAR 750 26558 500 NARROW TRANSPORT CONVEYOR page 2 SMART FEEDER SERVICE MANUAL a kar DETAIL ISSUE 09 99 PARTS SECTION I PAGE 51 SMART FEEDER SERVICE MANUAL ISSUE 09 99 PARTS SECTION I PAGE 52 750 26558 500 NARROW TRANSPORT CONVEYOR page 2 INDEX PART NUMBER 1 002 17309 0028 08408 0028 18366 0028 19599 0028 08409 6008 18635 014 91264 249 016
112. LEN SCREW 16 1143011 5 8 ALLEN SCREW 10 1143019 M8X12 ALLEN SCREW 4 1143028 10 25 ALLEN SCREW 4 1143039 M8X25 ALLEN SCREW 4 1143056 6 ALLEN SCREW 8 1150011 M6X20 DOWEL PIN 4 1150012 M6X6 DOWEL PIN 4 1122003 HEXHEAD NUT 6 1143003 M4X8 ALLEN SCREW 2 1143004 M4X10 ALLEN SCREW 14 1143006 M5X16 ALLEN SCREW 12 1143007 M5X10 ALLEN SCREW 16 1143011 M5x8 ALLEN SCREW 10 1143019 8 12 ALLEN SCREW 4 1143028 10 25 ALLEN SCREW 1143039 8 25 ALLEN SCREW 1143056 M4X6 ALLEN SCREW 1150011 M6X20 DOWEL PIN 1150012 M6X6 DOWEL PIN 2006617 STUD 2006618 STUD 2011605 SPACER BUSHING 2011619 SPACER RING 2012734 FLANGE 2012751 FLANGE 2012752 FLANGE 2012753 CLAMPING COLLAR 2012754 PULLEY 2012999 PULLEY 2013014 PULLEY 2013102 STUD 2017494 SPACER SHAFT 2017495 SHAFT 2017496 SHAFT 2017497 ROD 2017499 SHAFT 2017501 SHAFT 2017502 SHAFT 2017503 SHAFT rR Dt RJR NINI 00 N m AI AII AJIA 438 SERVICE MANUAL 02 01 071 26938 400 SECTION J 14 2017505 ROLLER 2021143 SPACER 2022500 PLATE 2022501 PLATE 2022502 PLATE 2022697 PLATE 2028216 BRACKET 2029056 COVER 2029057 COVER 2029424 GUIDE PLATE 2029464 GUIDE PLATE 2029465 GUIDE PLATE 2030565 RAIL 2029474 COVER RIGHT 2029475 COVER LEFT
113. NAL BLOCK ASSEMBLY 32 703 26611 500 FOLDER MOD page 1 34 703 26611 500 FOLDER MOD page 2 36 538 26297 500 AUXILIARY DRIVE 55 38 041 26521 500 DISCONNECT SWITCH ASSEMBLY 40 438 SERVICE MANUAL ISSUE 05 01 750 26525 500 WIDE TRANSPORT CONVEYOR page 1 44 750 26525 500 WIDE TRANSPORT CONVEYOR page 2 46 750 26558 500 NARROW TRANSPORT CONVEYOR page 1 49 750 26558 500 NARROW TRANSPORT CONVEYOR page 2 51 706 25697 400 GBR LINE CODE READ OPTION 53 088 26574 500 LASER SCANNER ASSEMBLY 55 191 26400 400 TOP MOUNT BAR CODE READER 57 088 27684 500 SINGLE CHANNEL DOUBLE PROBE READ 59 709 26907 500 TOUCHSCREEN ASSEMBLY 64 186 035700600 3208 DOCUMENT LOADER page 1 66 186 035700600 3208 DOCUMENT LOADER page 2 68 186 035700600 3208 DOCUMENT LOADER page 3 70 186 035700600 3208 DOCUMENT LOADER page 4 72 186 035700600 3208 DOCUMENT LOADER page 5 74 186 035700600 3208 DOCUME
114. NT LOADER page 6 76 750 26978 500 3208 FEEDER MECH INTERFACE 78 750 27737 500 3208 FEEDER ELECT INTERFACE page 1 81 750 27737 500 3208 FEEDER ELECT INTERFACE page 2 83 044 27423 400 EUROPEAN POWER CONVERSION 85 389 27146 400 BUHRS INTERFACE 87 PARTS SECTION I PAGE 1 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 2 738 26206 500 438 TOP ASSEMBLY CONVEYOR OPTIONAL a X 738 26206 500 438 ASSEMBLY INDEX PART NUMBER 005 27522 500 549 26603 500 579 26329 600 579 26341 600 702 26612 500 703 26611 500 041 26521 504 709 26907 500 438 SERVICE MANUAL DESCRIPTION CABINET ASSEMBLY FEEDER ASSEMBLY LEFT FEEDER COVER RIGHT FEEDER COVER ACCUMULATOR FOLDER DISCONNECT SWITCH TOUCHSCREEN ISSUE 05 01 PARTS SECTION I PAGE 3 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 4
115. OCK CODING ELEMENT KEY CODING ELEMENT KEY JUMPER BARS CONNECTOR PLUG CONNECTOR PLUG CONNECTOR PLUG SENSOR AMP ASSEMBLY VARISTOR ASSEMBLY DIN RAIL ISSUE 05 01 PARTS SECTION I PAGE 33 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 34 703 26611 500 FOLDER MOD page 1 See Section K for MB Folder parts manual BY N S 9 AL 8 EN 3 M 703 26611 500 FOLDER MOD page 1 INDEX PART NUMBER oNOOPOD 438 SERVICE MANUAL 014 31862008 020 26517 600 020 26537 600 021 SB100012 041 26521 500 124 26540 600 169 26539 600 169 26543 600 186 034007658 502 26799 500 526 26740 500 526 26741 500 538 26297 500 584 26507 600 584 26510 600 DESCRIPTION BOLT HH 312 18 X 50 CONVEYOR SUPPORT FRAME CONVEYOR SUPPORT SNAP BUSHING DISCONNECT SWITCH COLLAR MOD TIE BAR BAR MOD FOLDER MB see Section K FOLDER DRAWER MOD D C CONTROL CABLE CONTROL CABLE AUXILIARY DRIVE ASSEMBLY LOWER GUARD BRACKET AUX GEAR ISSUE 05 01 PARTS SECTION I PAGE 35 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 36 703 26611 500 FOLDER MOD page 2 Ry MOUNTED ON INSIDE
116. PS1 5 12 12 1 7 24 VDC Power Supply PS1 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 43 SECTION WIRING BOARD INFORMATION SECTION E PRINTED WIRING BOARD INFORMATION 1 CPU 486 MCM DX CARD sssensensonsensonsnnzznnensansensensensensensnnsensenseneene 2 E ta Features ae 2 NAAA AAA tereti ene eter ern 2 E TesSpecifications aie ee aa EHE 2 oe 3 2 144 4 Peatutes seda eor ERE EE EROR EE EM prep edt 4 E 2b General Description 4 E 26 Sp cifications eere ERE een 4 E 2d Configuration sense ses es 4 SVGA Video Card u srsussnssnssuesnssnssnesnssnssussnennssusnnsnnssusnnsnnssnssnsnnssnsnnsnansen 5 E Be reri 5 E 3b General 5 Specifications s en o HP 5 Serial Card 6 E 5 Single Channel Read 7 E 6 GBR TJ Line Code Card eee eee e eese eene 0002000022000 0 000000000 sena 8 B H Read 8 438 SERVICE MANUAL ISSUE 05 01 PRINTED WIRING BOARDS SECTION PAGE 1 438 SERVICE MANUAL ISSUE 05 01 PRINTED WIRING BOARDS SECTION PAGE 2 E 1 C
117. PU 486 MCM DX CARD VGA controllers sound and speech modules SCSI GBR Part Number 042 26932 500 controllers and literally hundreds of other options available form WinSystems and variety of vendors supporting the E 1a Features PC 104 standard Up to 32 megabytes of factory installed Processor Rates of 25 to 50Mhz and up to 100Mhz DRAM is supported on board An onboard Silicon Disk socket supports a solid state disk of up to 1 Megabyte in size using clock doubled CPU s M and can utilize SRAM PEROM Flash EPROM or the M Full PC AT Hardware Software Compatibility i e 16 Bit PC 104 Expansion Bus Systems Disk On Chip as the disk media Boot capability is 32 Mb of ruggedized onboard provided onboard and a setoff utilities and drivers are e Two Serial Ports with RS 232 RS 422RS 485 provided to make silicon disk based system very user friendly e Standard Centonics Parallel Printer Port TM e Watchdog Timer with Power Fail Reset E 1c Specifications 16 Bit Dual IDE Disk Interface Electrical e 5 Volt only operation Bus Interface STD 8088 188 Compatible PC 104 8 bit 16 bit expansion bus E 1b General Description System Clock Jumper Programmable form 2Mhz to The MCM DX is a small high performance embeddable 100Mhz computer system a single STD BUS board It can be Interrupts TTL Level input populated with any of the popular 486 Family of chips It s VCC 5V 5 at 930 mA typical at
118. R INFORMATION SECTION D PAGE 24 Expected Page One error Y Is the problem corrected by any of the following tests e Check read setup again particularly focus e Check for correct feed speed e Check speed sensor for proper operation N Check for failure on the CPU replace as necessary Bad e Bad software Group Out of Range error Y Is the group code in the range 0 7 Check that code is OK Out of Range error similar to Group Out of Range error page range must be within 1 7 Presets Corrupt error a CPU 486 error that would likely occur on power up Yes No EOG Are Same error this error is only associated with European machines Y N Is the problem corrected by any of the following tests Check read setup again particularly focus Check for correct feed speed Check speed sensor for proper operation N Check for failure on the CPU replace as necessary Bad UARTs Bad software 0 4 ACCUMULATOR SECTION D 4a Description Fed by the Feeder Section the accumulator is used to group up to seven documents before it sends them to the folder Plastic wedge stacking ramps position pages sequentially Stacking rollers are used to stop the paper and hold it in position When released the stacking rollers drive the collected pages out of the accumulator TheDump Clutch activates the stacking rollers releasing the accumulated pages A Stack Sensor
119. ROCEDURE FOR FEEDER SPEED IS TOO SLOW Remove the covers from the feeder Does the feed motor turn on Y Is there voltage at the connector that feeds the motor when the RESET ON key is pressed Y N e Check fuse F7 e Check KBIC Controller board Replace if necessary the Feeder Drive Motor REP 8 4 Enter Diagnostics Select Display status of Feeder Speed Encoder input opto 0 3 Change input to ON does LED 3 on opto rack 0 light Y N 4 Check the optical relay Check optical relay fuse Enter Diagnostics Select TEST Speed Option Does the Feeder speed indicate 50 IPS Y N Adjust the speed of the Feeder Replace the speed sensor Replace the KBIC Controller REPAIR CHECKOUT PROCEDURE FOR FEED SENSOR FEED SENSOR REFER TO SECTION F FEEDER SCHEMATIC Enter the TEST menu from the VIP display Select INPUT from the submenu and select Feed Sensor input Repeatedly block the feed sensor with a single piece of paper As the sensor is blocked the audible beep is heard Does the red LED on opto 0 0 opto module on opto rack 0 illuminate each time the sensor is blocked and go out when the sensor is unblocked Y N Is the green LED ON Adjust the sensor N Check a different input to ensure the audible signal on the display is working Check the wiring between the feed sensor and the opto rack If the wiring required correction does this correct the problem Y N Make sure senso
120. RT BAR IDLER SHAFT SHAFT UPPER DRIVE SHAFT UPPER EXIT GUIDE LOWER EXIT GUIDE SUPPORT PLASTIC PIVOT BLOCK BUSHING SPACER IDLER ROLLER 706 25697 400 GBR LINE CODE OPTION SMART FEEDER SERVICE MANUAL ISSUE 09 99 PARTS SECTION I PAGE 53 SMART FEEDER SERVICE MANUAL ISSUE 09 99 PARTS SECTION I PAGE 54 706 25697 400 GBR LINE CODE READ OPTION INDEX PART NUMBER DESCRIPTION 1 002A 16457 004 THUMBSCREW 2 002B 08126 DUAL READ ENCODER CABLE 3 002B 18518 ENCODER 4 007 25586 600 READ HEAD ADJUST BRACKET 5 007 26925 600 BRACKET MOUNT 6 007 26926 600 BRACKET READER 7 014 082511040 SHSS 8 32 X 25 BRASS 8 042 25272 500 SINGLE CHANNEL READ BOARD 9 042 26622 500 GBR OMR SBX ASSEMBLY 10 088 25588 500 READ HEAD ASSEMBLY 11 192 50122302B FIBER OPTIC READER PROBE 12 595 25585 600 SHAFT 13 595 25698 600 STUB SHAFT 14 600A 18374 PULLEY 15 600A 18378 BELT 088 26574 500 LASER SCANNER ASSEMBLY
121. RV EOG GS1 GS2 GS4 GS8 PS1 PS2 54 NOTE Presence of bar is binary 1 and the absence of bar is binary 0 The GRV mark must be located in the first position The EOG PAR GSn and PSn marks may be shifted in the bank of marks The GS grouping and the PS grouping must be located as sets however Probes A B Select the reading probe to be used INSTALLATION SECTION A PAGE 32 LIEU LEM Line Read Setup 2 Jorr gt m Process Status Bit Weight Page and Group marks can be arranged as Most Significant Bit First MSB or Most Significant Bit Last MSB First is the first bit encountered when reading MSB Last is the last bit encountered when reading Example MSB Last Example MSB First GRV GRV EOG EOG GS1 GS8 GS2 GS4 GS4 GS2 GS8 GS1 PS1 4 52 54 438 HD SERVICE MANUAL 071 26938 400 PS2 PS1 PAR ISSUE 05 01 Calibration NOTE Calibration is normally to be used by the service technician only See section GBR Line Code Read for related information The Line Code Recognition system can be calibrated to the particular machine in which it is installed Calibrating the Line Code Recognition system to the particular machine eliminates parts tolerance problems and provides a method of recalibration once parts have become worn Calibration of the machine is provided for 1 10 1 8 and 1 6 code spacing There is a different calibr
122. S detects paper arriving in the accumulator while the Accumulator Sensor indicates presence or absence of a package in the accumulator It also monitors for successful package discharge when the dump clutch has been engaged 0 46 Accumulator Clutch and Brake Adjustments The Accumulator Clutch is designed with a preset gap no adjustments are possible or necessary There should be a slight amount of rotational freeplay in the clutch body to prevent binding ACCUMULATOR CLUTCH amp BRAKE SETTING The Accumulator Brake does require a gap setting of 005 This setting is critical too tight and the drag on the clutch will cause premature wearing of the clutch and the brake Too wide of a gap and the Stacking Rollers won t stop the documents correctly in the Accumulator 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 25 438 SERVICE MANUAL ISSUE 05 01 D 4c Accumulator Dump Roller Replacement To replace the dump rollers it is first necessary to disconnect the accumulator from the folder 1 2 3 Disconnect all electrical connectors to the feeder Remove the left feeder cover Loosen the two thumbscrews that latch the feeder to the accumulator Loosen the accumulator to feeder drive belt tensioner and remove belt 5 Move feeder out of way 6 Remove both accumulator side covers 7 Remove the lower fold plate sliding cover by first removing the two stop screws on the slid
123. SSUE 05 01 PARTS SECTION I PAGE 30 702 26612 500 ACCUMULATOR MOD See Section J for MB D Accumulator parts manual 702 26612 500 ACCUMULATOR MOD INDEX PART NUMBER 00 4 09 438 SERVICE MANUAL 007 26561 600 013 26562 600 014 25 31308 020 26515 601 020 26515 602 020 26563 600 020 RA006C0803 021 SB750625 024 26724 500 025 25817 000 041 26739 500 041 35701 074 26614 500 121 26564 500 172 10941A1032 186 034007665 526 26740 500 526 26741 500 563 26513 600 579 26346 600 579 26514 600 579 26560 600 579 26677 600 584 267 79 600 002 16497 005 1 030 344 144 27015 600 118 27016 600 118 27017 600 DESCRIPTION COVER HINGE NUT PLATE SHOULDER 5
124. T INTERFACE page 1 INDEX PART NUMBER DESCRIPTION 1 032 00080250 FUSE 8 250 5 2 091 27411 500 ADAPTOR PLATE ASSEMBLY 3 526 27407 500 LINE ASSEMBLY 4 526 27408 500 470 INTERCONNECT CABLE 5 526 27409 500 E STOP CABLE 6 526 27511 500 AUTO MODE CABLE 7 750 26978 500 3208 FEEDER MECH ASSEMBLY 750 27737 500 3208 FEEDER ELECT INTERFACE page 2 ON EN 2 53 4 SECTION D D H n e d x N i RICHT SIDE VIEN SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 83 SMART FEEDER SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 84 750 27737 500 3208 FEEDER ELECT INTERFACE page 2 INDEX PART NUMBER DESCRIPTION 1 024 10300226 END STOP 2 024 26789 000 THROUGH TERMINAL BLOCK 3 024 26790 000 END PLATE 4 024 26791 000 ADJACENT JUMPER 5 025 25817 000 FERRULE 22 GA 6 030 26793 000 OUTPUT MODULE 7 045 022130 WIRE BLK 22 GA 8 091 27411 500 ADAPTOR PLATE ASSEMBLY 9 526 27409 500 E STOP CABLE 10 526 27511 500 AUTO MODE CABLE 11 750 26978 500 3208 FEEDER MECH INTER
125. TANDOFF 10 32 1 875LG SPACER 25CL 187LG SPACER 25CL 375LG TIMING PULLEV 25T TIMING PULLEV 20T TIMING BELT 18PL TIMING BELT 22PL TIMING BELT 23PL INFEED GUIDE TIE BAR HANDLE ISSUE 05 01 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 526 26327 500 579 26407 500 579 26535 600 584 26516 600 600A 17700 600A 17735 600A 17785 600B 16349 027 600A 16349 034 600B 18108 600B 18109 600B 18639 600B 18640 600B 18644 600B 18649 600C 17708 600C 17709 600C 18716 600D 17724 600D 18035 600D 18633 TRANSPORT CABLE COVER SHIELD RIGHT CONVEYOR SUPPORT DRIVE PULLEY RIGHT PIVOT STOP LEFT PIVOT STOP GEAR HUB CLAMP RIGHT HINGE LEFT HINGE SHAFT SHAFT DRIVE SHAFT SHAFT RIGHT CONVEYOR RAIL LEFT SUPPORT RAIL SHIELD LEFT CONVEYOR SIDE PLATE RIGHT CONVEYOR SIDE PLATE SHIELD PARTS SECTION I PAGE 45 438 SERVICE MANUAL ISSUE 05 01 PARTS SECTION I PAGE 46 750 26525 500 WIDE TRANSPORT CONVEYOR page 2
126. VE POTENTIAL WAT BLK ORN THE INSERTER IS RUNNING MA IM CONNECT TO POINT WITH CREATEST NEGATIVE POTENTIAL CONNECTION BETWEEN STATION 1 CONTROL SWITCH AND STATION 1 SOLENOID BREAK CONNECTION CONNECT TO SWITCH CONNECT POINT WITH CREA ENTIAL PROBABLY SWITCH Lu ER ABOV EJ 5 CONNECT SOLENOID CONNECT TO POINT WITH CREA ENTIAL PROBABLY SOLENOID RED GR gt CONNECT THESE TWO WIRES IN SERIES WITH STATION 1 ERROR DETECT SWITCH SEE NOTE 3 CONNECT TO POINT WITH GREATEST POSITIVE POTENTIA CONNECT TO POINT WITH GREATEST NEGATIVE POTENTIAL CONNECTIO WHT RED RED e 4 WHT RED BLK a WHT RED CRN 2 NOTE 1 GENERAL NOTE FOR INSERTERS WITH CONTROL CONTROL VOLTAGES MUST 12 2BOVAC NOTE 2 ASSUMES THAT DETECT CIRCUIT CONNECTS TO CIRCUIT GROUND TO CREATE AN ERROR NOTE 3 ONLY MAKE STATION 1 CONNECTIONS IF 420 IS NOT LOCATED AT STATION 1 LE OPEN ENDED 002C 07968 AC DC CONTROL CABLE E un N al T 5 NSTALLATION INSTRUCTIONS SECTION G INTERFACE WITH OPTIONAL EQUIPMENT G 1 REMOVAL HOPPER SIDE PLATES G 2 REMOVE HOPPER GUIDE REMOVE SINGULATOR FINGER G 4 438 INTERFACE G 5 BUHRS INSERTER INTERFACE OPTION 438 SERVICE MANUAL ISSUE 05 01 438 is designed to be run on lin
127. al group selection for 1 to 7 sheets Counter Modes Total count batch count resettable count 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION A PAGE 11 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION A PAGE 12 Output Conveyor Options Version 1 with shingling output conveyor stacker Version 2 with intelligent transfer conveyor interface to gripper arm of inserter s insert station Version 3 with a buffering intelligent transfer conveyor interfaces to an open feed station of inserter The GBR 438 3 can also convert an intelligent continuous form mail inserting system to a cut sheet operation Controller Adjustable operator s panel with readout and touch screen access to all system functions System is microprocessor controlled with self diagnostics and error display including double misfeed and jam detection Electrical Service 208 volts 3 phase Y 20 amp 4 pole 5 wire grounding use L21 20R 220 volts 1 phase 20 amp 3 pole 4 wire grounding use NEMA L14 20R 1 000 BTU hr Fuse List Refer to Section D10 Dimensions includes feeder accumulator folder and transfer conveyor Length 106 mm Width 26 Height 58 mm Weight Net approx 725 Ibs kg Read Options Line Code B H or GBR Bar Code 5 RUN SCREEN This screen is displayed continuously for informational purposes until Test or Setup is selec
128. andee thes nale ga i 0 5mm plates The delivery 5 shaft would then be n mber amp 27 the roller turn the setting knob counter gt Rollers 4 5 6 amp 7 are not part of folder with 2 fold When the roller gap is changed by more plates The delivery shaft would then be number 4 an 0 5mm the valies cales must added setting knobs are equipped with scales 1 With Example 0 5 2 16 1 0 66 mm their help settings with a precision of 0 1 mm are possible 438 SERVICE MANUAL FOLDER FOR 456 APPLICATIONS IL if THESE NUMBERS ON DIA AN 124 Standard 438 Folder Knob Setup ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 39 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION D 6 TRANSFER CONVEYOR Description The transfer conveyor is an articulated belt system which presents the nest folded document s to the Inserter gripper arm D 6b Timing Demand switch on off timing is critical The setup of this timing permits the 438 to achieve optimal handoff to the Inserter The Demand switch should turn on contacts closed when the gripper arm is approximately perpendicular to the deck of the Inserter The Demand switch should then turn off contacts open as the gripper arm completes it s backwards motion and starts moving toward the Transfer conveyor This timing setup is also us
129. ated in a low to high voltage transition TRIP POINT 2 controls the voltage level at which an interrupt will be generated in a high to low voltage transition INSTALLATION SECTION A PAGE 27 438 HD SERVICE MANUAL 071 26938 400 A 8b Setting Up the GBR Line Code Reader Setting the Probe The most critical area of adjustment is the read sensor focus The mechanical position of the read sensor must be adjusted to obtain the proper size and focus of the light emitted from the read sensor Without the proper focus the read sensor cannot accurately interpret the GBR line code 1 Position the read head assembly to aim the light through the hole in the paper guide rail The lowest point on the read head should be 1 2 to 5 8 inch away from the paper surface Place a document with the GBR line code near the light from the read sensor Turn the read lamp on Go to SETUP gt LINE READ gt LINE READ SETUP 4 Enter LAMP SETTING 255 by pressing the or keys Loosen the read sensor locking screw and push the read sensor completely into the housing Observe the light beam image It should be centered on the hole in the rail and appear to be out of focus as it is drawn out of the housing the image will appear to come more and more into focus Proper focus is obtained when the image is at its smallest size and a very slight halo appears around it The width of the light beam image on the paper not including the halo should be equal
130. ation number stored in battery backed memory for each type of code spacing This means a machine must be calibrated when the proper line code spacing is selected Once a machine has been calibrated for 1 6 1 8 or 1 10 spaced codes it will operate properly until the parts on the machine become severely worn The machine is calibrated by running a special Calibration sheet through the machine The Calibration document has two precisely placed marks on the document These marks provide the needed reference points to calibrate the machine The same sheet is used for all three settings Description Of A Calibration Document A Calibration document has two precisely placed Line Code marks on a document The first Line Code mark is placed one inch from the leading edge of the document The second Line Code mark needs to be precisely placed 6 inches away from the first Line Code mark No other marks can be in the area between the two marks This will give the Line Code Recognition system the expected reference distance to calibrate to the machine The Line Code Recognition card uses the two marks on the Calibration document to count the number of encoder signals which occur between the marks If the number of encoder signals counted are within 15 96 of the expected number of encoder signals it is considered a valid calibration value INSTALLATION SECTION A PAGE 33 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION A PAGE 3
131. ator clutch is on adjusted for speed Adjust up so pack fully exits Adjust down if next pack is partially pulled under rollers TouchScreen X Correction e Constant value for touch sensing Adjust up to move sense right Adjust down to move sense left TouchScreen Y Correction Constant value for touch sensing Adjust down to move sense up Adjust up to move sense down Paper Demand Time Time msec waiting for paper stack switch in feeder to be satisfied by infeed Max Xcvy Stations Max Number of package positions in Xcvy Test ExitComm Test List Switch 0 Noextra ExitComm Comm3 list messages e 1 Extra ExitComm list messages times msec Demand time receive character for Sure Feed Exit Demand Switch Applies to HopperFill and Conveyor e 0 No Exit Demand required e 1 Exit Demand required for Conveyor for Sure Feed Exit Demand Time Out 22 3000 23 250 24 170 200 170 200 25 1 26 0 27 4444 28 1 29 3 30 n a 438 SERVICE MANUAL 3000 250 0 4444 1 2 e Default 60 60 seconds to shut down on no demand Range 0 to 999 seconds Xcvy Jam At Out Time e Default 3000 3000 msec to pass pack through exit sensor Range 0 to 9000 msec Xcvy Jam At In Time e Default 500 500 msec to pass from folder to in sensor Range 0 to 9000 msec Feed to Accum Time e Default 170 170 msec for the lead edge of paper fed at the feed sensor to the lead edge entering the accumulator Range 0 to 5000
132. be displayed when the cursor is positioned on its Rack and Opto Location block Inputs will change state when sensors are blocked or encoders are rotated Use the Toggle button to toggle the outputs on and off Interlocks must be closed and Master Relay e output 1 3 must be toggled ON for this to function Opto Rack 9 9 9 0 1 RED RED RED Opto Location on Opto Rack 00 23 RED B 18 HITE o 900 100 5 2 O od ojo WHITE o S 5 m 8 O 14 HITE O 13 0 svo 087 MODULES jun HITE 12 a non poooooooooooooog 3 9 1 jut o 9 4 gc 3
133. bulkhead J16 to floppy drive Hou H 438 SERVICE MANUAL ISSUE 05 01 PRINTED WIRING BOARDS 3 438 SERVICE MANUAL ISSUE 05 01 PRINTED WIRING BOARDS SECTION E PAGE 4 E 2 1 0 144 CARD GBR Part Number 042 26750 500 Environmental Operating Temperature 0 to 65 C E 2a Features Non Condensing Humidity 5 95 e 144 Digital I O pins per Extensive Interrupt Capabilities bit selectable E 2d Configuration e Interrupt ID register for more efficient ISR s e Jumpers as shown in diagram e Each pin capable of sinking 12ma for use with Opto J1 to left opto rack modules J2 to right opto rack e Read back Input available for each pin e J3 to the feeder brake e 50 Pin connector directly interfaces to Opto Racks J3 to ink mark sensor when applicable 5 volt only operation 8 bit STD Bus interface gt 1 E 2b General Description The 144 is a low cost high density card with extensive EE interrupt capabilities i For a given configuration half of the pins have interrupt capabilities Interrupts are programmable on a bit by bit Bis basis for enable and edge polarity 55 All lines are Open Collector I O In addition
134. ch ON page passing out of Acc Presence Sensor EVENT CHECK NoDumpTimer CHECK VALUE 150 msec Sheet Length 150 Speed ADJUST VALUE ANALYSIS Time exceeded C 3d 14xxx Folder Error Description 14001 Jam In Folder EVENT Accum Clutch ON to lead edge Folder Exit Sensor EVENT CHECK FolderExitTimer CHECK VALUE 400 msec PROBLEM ANALYSIS SECTION C PAGE 12 ADJUST VALUE Engin Value 4 ANALYSIS Time exceeded 14002 Jam At Folder Exit EVENT Accum increment Lead edge at Folder Exit Sensor decrement EVENT CHECK PackageCounter ERROR gt 2 CHECK VALUE 2 ADJUST VALUE Engin Value 4 14820 SPEED LOW EVENT Folder Encoder Sensor EVENT CHECK Calculate and Average speed CHECK VALUE 25 inches per second ADJUST VALUE ANALYSIS Speed less than value C 3e 15xxx Xfer Conveyor Xfer Cvyr Xcvy Error Description 15001 Jam Error EVENT Pack at Sta 1 In Sensor increment Pack at Xcvy Out Sensor decrement EVENT CHECK PackageCounter ERROR ON gt 5 CHECK VALUE 5 ADJUST VALUE Engin Value 18 15002 Jam At In Sensor Error EVENT INSERTER Xcvy Clutch ON to Pack out of Xcvy Sta 1 In Sensor EVENT CHECK JamaAtinTimer CHECK VALUE 500 msec ADJUST VALUE Engin Value 23 ANALYSIS Time exceeded 438 SERVICE MANUAL ISSUE 05 01 PROBLEM ANALYSIS SECTION C PAGE 13 438 SERVICE MANUAL ISSUE 05 01 PROBLEM ANALYSIS 15003 15002 1
135. ck for failure on the CPU replace as necessary Bad UARTs Bad software The page that was fed did not follow the selected roll sequencing pattern If the roll is not out of sequence check to see that the proper barcode is printed on the page and that the barcode matches the specifications Check to see that the proper barcode job is selected just Paper jam Reader board failed nn029 nn030 nn031 nn032 nn033 nn034 nn035 nn036 nn037 nn038 nn039 EXPECTED READING READER REBOOTED computed in action CALIB IN RANGE NO RANDOM CHECK MK UNEXPECTED RANDOM CHECK PACK LARGER THAN SET PACK LESS THAN SET GROUP NUMBER CHANGED IN SET LAST SET SAME GROUP NUMBER MAX SHEETS IN ACCUM UNEXPECTED EOG 438 SERVICE MANUAL Reader encoder bad Blank page Read encoder failed Paper jam Feed sensor out of adjustment Reader encoder failed Bad read board Calibration was successful Incorrect document in accumulator Random check mark not set correctly in Setup Code bad or misprinted Incorrect document in accumulator Random check mark not set correctly in Setup Code bad or misprinted There were more sheets in the package than expected There were less sheets in the package than expected very page within a set is supposed to have the same group number and he page that was just fed did not If the group d
136. cked by a sheet of paper Y N Make sure sensor amplifier is set for Dark ON correct if necessary Check wiring between the Control Box and keyboard Place a sheet of the current stock in the sensor area and adjust the sensor so that the red LED goes out with a sheet blocking the sensor Check that printing on the stock is not interfering with the sensor Does the audible signal beep and LED on opto 0 18 light when a sheet is under the sensor Y N Check a different input to ensure the audible signal on the display is working Check the small fuse for opto relay 18 e Check the opto relay Is there 24 VDC at TB2 1 and TB2 2 Y N Check the connection from the controller to the Feeder Check the wiring Check the power supply 51 REPAIR CHECKOUT PROCEDURE FOR SMALL Clear the paper that was jammed the machine and remove any obstructions Does the paper move through the feeder properly Y N Check that the paper size setup is correct Check that the guide rails ensure the paper passes under the Feed and Double Detect sensors Ensure that the pullout roller does not force the paper to ride up on the paper guides Check that the paper stock being used is not damaged or curled Adjust the singulator roller Adjust the auxiliary feed belts REPAIR INFORMATION 438 SERVICE MANUAL ISSUE 05 01 SECTION D PAGE 17 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 18 REPAIR CHECKOUT P
137. d explanation of character length in Bar Read Setup 2 Eliminated all 1 30 in the Bar Read Setup 2 section 2 Change CPU 186 to CPU 486 2 places C 3b Added Analysis and Initial Action for 12821 MISSED PAGE C 3f Added read error probable causes and remedies D 2b Change CPU 186 to CPU 486 D 3 RCP for Feeder Speed Encoder Change CPU 186 to CPU 486 2places RCP for Feed Sensor Change CPU 186 to CPU 486 RCP for Two Sheet Sensor Change CPU 186 to CPU 486 RCP for Read Board Error Presets Corrupt Change CPU 186 to CPU 486 D 4b RCP for Stack Sensor Presets Corrupt Change CPU 186 to CPU 486 RCP for Accumulator Sensor Change CPU 186 to CPU 486 RCP for Accumulator Dump Clutch Change CPU 186 to CPU 486 D 4c Added section for Accumulator Dump Roller Replacement D 6c Change CPU 186 to CPU 486 E Added PWB information H 3 Added 30 Bar Read Commport setting added 191 26400 400 Top Mount Bar Code Reader Added 088 27684 500 Single Channel Double Probe Reader Added 041 26521 500 Disconnect Switch Assembly Added 186 035700600 3208 Bulk Loader Added 750 26978 500 3208 Feeder Mechanical Interface Added 750 27737 500 3208 Feeder Electrical Interface Added 044 27423 400 European Power Conversion Added 389 27146 400 Buhrs Interface 15 changed item 26 part number l 11 changed item 10 part number l 17 added parts 14 15 and 16 l 21 changed item 5 part number l 31 added note to see section J l 35 added note to see sect
138. drive belts excess static Verify all cable connections are properly mated and all applicable sensor connections as per application are mated properly and not obstructed In SETUP verify that correct input parameters are selected Verify the Emergency Stop button is not actuated 0 16 List Repair Checkout Procedures RCP REPAIR CHECKOUT PROCEDURE FOR PAPER COULD NOT BE 12 REPAIR CHECKOUT PROCEDURE FOR FEEDER 13 REPAIR CHECKOUT PROCEDURE FOR FEEDER SPEED 14 REPAIR CHECKOUT PROCEDURE FOR EXTRA PAGE FED 2 2226 reete ete tet eh eo eo E e VO EE E E E REY e d 15 REPAIR CHECKOUT PROCEDURE FOR PAPER JAM IN FEEDER 16 REPAIR CHECKOUT PROCEDURE FOR SMALL SHEET 5 20 nut ee ga eint teer 17 REPAIR CHECKOUT PROCEDURE FOR FEEDER SPEED IS TOO 22 22400 2 204 444000 00 00000000 innen 18 REPAIR CHECKOUT PROCEDURE FOR FEED 5 19 REPAIR CHECKOUT PROCEDURE FOR TWO SHEET SENSOR 906 20 REPAIR CHECKOUT PROCEDURE FOR READ BOARD 21 REPAIR CHECKOUT PROCEDURE FOR STACK 5 5 26 REPAIR CHECKOUT PROCEDURE FOR ACCUMULATOR SENSOR
139. e Code marks is required to be recognized on a single document each additional channel requires another Line Code Recognition system The GBR Line Code reader contains an intelligent analog section that reads GBR line code It consists of an 8051 GBR Line Code Reader Card STD 80 an SBX Reader Card TJ Board an encoder and one or two fiber optic read probes The intelligent analog section allows the reader to be setup through the 438 s touchscreen The GBR Line Code reader uses an analog signal to read code as it passes by the fiber optic sensor The reader board is intelligent because the variables used to generate this analog signal are not hardwired into memory but can be modified through software The reader can be adjusted to account for variables such as e Paper color changing from job to job e Code not being printed to specification resulting in more reliable reading from the 438 438 HD SERVICE MANUAL 071 26938 400 ISSUE 05 01 Reader Board Values that can be Adjusted Through The 438 Touchscreen Refer to Line Read Setup 4 e GAIN controls the amplitude of the 0 5 volt analog signal OFFSET 1 controls the initial DC voltage added to the analog signal to catch the lead edge of the page e OFFSET 2 controls the DC voltage added to the analog signal when reading the code LAMP controls the brightness of the reader probe TRIP POINT 1 controls the voltage level at which an interrupt will be gener
140. e bar job selected to its defaults erasing any modifications that may have been done in the setups Press OK to set the job Bar Read Setup 1 Page Seq Mark Demand Feed Purpose Identify each individual page within a package The sequential incrementing of the number ensures the documents are assembled in the proper order e Up Min to Max within sets e Page Down Max to Min within sets e Roll Up Min to Max to Min across sets Roll Down Max to Min to Max across sets Count NA None e Min 0 to 1 e Max 0 to 999 Ink Mark e to drive an ink zip mark mechanism downstream Meter Divert e to drive a divert mark mechanism downstream Parity Mark Not functional at this time Purpose Adds parity error checking to the code Normal Mark is on the last page fed Usage This location is used to maintain an even number of solid Reverse marks within a code Yes No NA First n A Note The fields that are marked Optional can be eliminated by operator configuration of the machine However when a data field is eliminated Group Seq package security and integrity suffers Purpose Identify each page as being a part of an individual package The sequential incrementing of the number ensures the document s printed sequence is maintained Subset Mark NA Up Match in set Min to Max to Min Down Match in set Max to Min to Max Random Mark NA Matchi
141. e clutch engages feel with fingers or listen for click As the clutch engages observe opto 0 20 opto module 20 on opto rack 0 Does the red LED illuminate each time the clutch engages and go out when the clutch disengages Y N Check the wiring between the accumulator dump clutch and the opto rack If the wiring required correction does this correct the problem Y N Check the pico fuse of the opto module Replace the output opto module if necessary and repeat the test Does the clutch engage Y N Does LED light when ENTER is pressed Y N Check wiring to clutch T Replace the CPU 486 PWB Check the accumulator sensor 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 29 438 SERVICE MANUAL D 5 FOLDER FUNCTION D 5a Description Fed by the Accumulator Section the folder is capable of placing 1 to 5 folds in a C Z or 7 double V configuration See Fold Capacity Chart at the end of this manual Adjustable buckle plates set the distance of the fold from the edge of the paper Fold rollers nip the paper as it is buckling creating the fold A 110VAC motor drives all folder shafts and rollers The folder speed encoder located on the infeed roller shaft provides a folder speed signal Depending of the particular configuration document s exit the folder one of three ways 1 Shingling conveyor stacker The stacker allows easy continuous removal of document s while avoiding any loss of sequence
142. e track 8 Remove the green folder to accumulator drive belt 9 Carefully remove all wire ties for left side folder to accumulator terminal block wire bundle 10 Place a table beside the folder must be within 3 in height of the bottom of the accumulator 11 Remove the two nuts that secure the accumulator to the folder 12 Carefully pivot the accumulator onto the table beside the folder REPAIR INFORMATION SECTION D PAGE 26 REPAIR CHECKOUT PROCEDURE FOR STACK SENSOR STACK SENSOR REFER TO SECTION ACCUMULATOR Enter the TEST menu from the VIP display Select INPUT from the submenu and select Stack Sensor input Repeatedly block the stack sensor with your hand or a piece of paper As the sensor is blocked the audible beep is heard and opto 0 1 opto module 1 on opto rack 0 red LED illuminates each time the sensor is blocked and goes out when the sensor is unblocked Y N Check a different input to ensure the audible signal on the display is working Y N Check input opto 0 1 opto module 1 on opto rack 0 Does LED light when sensor is blocked Y N Check the wiring between the stack sensor and the opto rack If the wiring required correction does this correct the problem Y N Check the pico fuse of the opto module Replace the input opto module if necessary and repeat the test Does the LED illuminate Replace the CPU 486 PWB Y Run the machine Check the paper transport Are belts carrying paper
143. e with the inserter It can be docked to any of the insert stations however station 1 15 preferable Before the 438 may be mated up to the inserter there are a few pieces on the inserter which need to be removed or repositioned The parts to be removed are the hopper side and rear plates T plate and insert cushion cup The singulator finger and cushion cup mount must be repositioned A demand switch must be added to the transfer conveyor These changes may be done once and left that way so the 438 may be used again without going through them each time If this is done however this station will not be usable in normal operation INSTALLATION SECTION G PAGE 1 438 SERVICE MANUAL ISSUE 05 01 G 1 REMOVAL OF HOPPER SIDE PLATES NOTE View of Insert Hopper is from 438 side of inserter 1 Remove four screws holding side plate adjustment shaft blocks 2 Remove shaft E clips 3 Unlock right side plate and slide off end of shaft 4 Slide left side plate out to end of shaht near adjustment knob The shaft and side plate now may be removed you may find it necessary to turn the plate and shaft to free it from the inserter G 2 REMOVE HOPPER GUIDE 1 Remove cover directly behind insert station 2 Unlock mount remove outer snap rings 3 Slide shaft to right the left side mounting bracket will drop down under inserter deck 4 Slide shaft to left the right slide bracket will drop 5 Remove rear plate Remove two Ph
144. echnical Bulletin 271 27819 400 for further grounding instructions 12822 12823 12825 12826 LONG PAGE FED EVENT Feed Clutch ON page lead edge and trail edge through Feed Sensor EVENT CHECK JamTimer CHECK VALUE 150 msec Sheet Length 150 Speed ADJUST VALUE ANALYSIS Time exceeded EXTRA PAGE WAS FED EVENT Page lead edge at Feed Sensor EVENT CHECK Feed Sensor CHECK VALUE ADJUST VALUE ANALYSIS Page lead edge at Feed Sensor Feed not processing FEED TO ACCUMULATOR JAM TIME EVENT Feed Clutch ON page lead edge and lead edge through Accum Sensor EVENT CHECK FeedToAccumTimer CHECK VALUE 170 msec VALUE 160 Speed ADJUST VALUE Engin Value 24 ANALYSIS Time exceeded SPEED LOW EVENT Feed Encoder Sensor EVENT CHECK Calculate and Average speed CHECK VALUE 25 inches per second ADJUST VALUE ANALYSIS Speed less than value 438 SERVICE MANUAL ISSUE 05 01 PROBLEM ANALYSIS SECTION C PAGE 11 438 SERVICE MANUAL ISSUE 05 01 12827 FEED SENSOR COVERED EVENT Feed Sensor ON EVENT CHECK Check at Feeder Power On CHECK VALUE ADJUST VALUE ANALYSIS Feed Sensor ON C 3c 13xxx Accumulator Error Description 13000 Stack Error EVENT Page passing through Acc Stack Sensor EVENT CHECK StackTimer CHECK VALUE 500 msec ADJUST VALUE ANALYSIS Time exceeded 13001 Misfeed Error EVENT Acc Clut
145. ed to adjust dwell time for the Open Feed option SECTION D PAGE 40 Move Closer To Increase Duration To PF300 Folder Magnets Slide To Change gt Duration Magnetic Maanet Block j agnet Block i Be Rotate For Switch Enlarged Proper Timing at Left Xz1 Pack Length D Point at which gripper arm takes pack Demand switch turns ON 8 Demand switch turns OFF Transfer Conveyor Demand Switch Figure D 6c Exit sensor Test on the Transfer conveyor The Exit sensor on a 438 creates an interrupt to the control card This interrupt is what permits accurate positioning of packages on the Transfer conveyor Testing the interrupt communication is done in the following manner 1 Clear Transfer conveyor of all documents 2 Place a folded document approximately 1 2 inch before the Exit sensor on the Transfer conveyor NOTE Be sure the inserter is running to supply a Demand signal 3 Run the 438 and command the machine to Dump 4 The Transfer conveyor will index in response to the Dump command If the package that was placed just before the exit sensor stops at the discharge end of the Transfer conveyor the interrupt is being seen by the control card However if the document is throughout the end of the Transfer conveyor then the interrupt is not being seen by the control card NOTE The Interrupt signal enters the Control card CPU 486 at header J9 The signal comes from J10 a 50
146. er numeric values e Start Bit 0 to 20 Starting bit position within character Ink Mark Code e Start 0 to 30 Start character e Length 0 to 20 Number of characters Used with Normal A or Reverse A multiple character numeric values e Start Bit 0 to 20 Starting bit position within character PmDivert Code e Start 0 to 30 Start character The software permits a total of 30 characters in Bar Read however physically Length 0 to 20 Number of characters Used with that isn t always practical due to the length of the code For instance 3 of 9 code Normal A or Reverse A multiple character numeric is physically larger than 128 code not available on the 438 at this time A code values L excess of 15 characters becomes problematic with 3 of 9 code but a 128 Start Bit 0 to 20 Starting bit position within character code can easily exceed 20 characters Define the position in the barcode string to extract the information for the following A 9e Adjusting the Paper Guides Group Seq Code e 0 to 30 Start character In order for your laser scanner to read the bar code there can be nothing e Length 0 to 5 Number of characters blocking its path The Paper Guides provided with the Laser Option are Start Bit 0 to 30 Starting bit position within character custom adjustable for your specific code location e Length Bit 0 to 30 Number of bits Place these guides to provide as much support
147. evenly across the paper Page Seq Code path as possible without interfering with the lasers path Start 0 to 30 Start character e Length 0 to 3 Number of characters e Start Bit 0 to 30 Starting bit position within character e Length Bit 0 to 30 Number of bits 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION A PAGE 49 SECTION PREVENTIVE MAINTENANCE B 1 Test equipment and tools 1 B 2 General procedures 1 B2 a CLEANING THE MACHINE 1 B2 b LUBRICATION B 1 TEST EQUIPMENT AND TOOLS B2 a CLEANING THE MACHINE e Fluke Scope Meter The 438 should be cleaned daily to remove any dirt or dust e Standard amp Metric Hex Wrenches which may interfere with the operation of the machine Paper Small Blade Flat Screwdriver dust collected in motion areas could impede and or damage e Philips Head Screwdriver integral parts of the folder Paper dust can also impede read quality if it accumulates on the read heads and paper sensors Excess dirt or toner build up from laser printing on the feed 2 GENERAL PROCEDURES belts could result in damage to the material and or premature wear of the feed belts Therefore it is important to perform the following daily cleaning instructions 1 Clean ALL Feed Belts WARNING 2 Remove ALL Paper Dust 3 Clean the Fold Rollers 4 Clean the Machine Cabinets and Covers 2 1 Cleaning the Fold Rollers All accumulated paper dust should either be brushed or vacuumed from
148. he selected group sequencing pattern If the group is not out of sequence check to see that the proper barcode is printed on the page and that the barcode matches the specifications Check to see that the proper barcode job is selected page sequencing down and the last page fed was page 1 the Software expects the next page to have an end of set mark on it new set and highest page of that set or if 6 pages are fed into the accumulator the software expects the next page to have a subset mark or an end of group mark on it If an end of group mark was present check to see that the proper barcode is printed on the page and that the barcode matches the specifications Check to see that the proper barcode job is selected No code detected Check read setup again particularly focus Check for correct feed speed Check speed sensor for proper operation Check for failure on the CPU replace as necessary UARTs Bad software ISSUE 05 01 PROBLEM ANALYSIS SECTION C PAGE 15 438 SERVICE MANUAL nn004 nn005 nn006 nn007 nn008 nn009 SHORT GROUP DUPLICATE PAGE PAGE OUT OF SEQUENCE INVALID GROUP EXPECTED PAGE ONE GROUP NUMBER OUT OF RANGE ISSUE 05 01 PROBLEM ANALYSIS SECTION PAGE 16 Check the page to determine if error is valid Check read setup again particularly focus Check for correct feed speed Check speed sensor for proper o
149. he sensor is unblocked Y N Check a different input to ensure the audible signal on the display is working Y N Is the green LED ON Y N Agjust the sensor N Make sure sensor amplifier is set for Dark ON correct if necessary Check input opto 0 16 opto module 16 on opto rack 0 Does LED light when sensor activated Y N Check the wiring between the Double Detect sensor and the opto rack If the wiring required correction does this correct the problem Y N Check the pico fuse of the opto module Replace the input opto module if necessary and repeat the test Does the LED illuminate Replace the CPU 486 PWB Run the machine Check the singulator is it properly adjusted Y N Agjust the singulator If the components of the machine are operational and correctly adjusted make sure that the paper being run is of the correct quality and condition READ BOARD TO SECTION READER SCHEMATIC NOTE If read type is changed SETUP the 438 must be powered down and back up to clear and reset all read parameters Also make sure that the code is centered under the reader light Code offset from the reader light will give spurious signals Refer to the error code as it appears on the 438 display If GBR OMR reading is active perform test as described in section D3 c to help resolve code reading errors No Response Time out Y N Perform Read setup Is setup correct Power must be cycled ON OFF after a read
150. id not change within the set check to see that the roper barcode is printed on the page and that the barcode matches the specifications Check to see that the proper barcode job is selected ctf pH previous group had the same group as the current The maximum number of sheets set in the system has been reached Change setting if a larger pack size is desired The package size has exceeded the machines capabilities The end of group mark was read but not expected The document sequence is out of order isread Bar code misprinted ISSUE 05 01 PROBLEM ANALYSIS SECTION PAGE 19 438 SERVICE MANUAL nn040 nn041 nn042 nn043 nn044 nn045 nn046 NO RESPONSE TIMEOUT BAD READ bar read MAX PAGE NOT NO PAGES bar read INVALID GROUP NUMBER bar read BAD CHECK DIGIT bar read EXPECTED END OF SET bar read EXPECTED PAGE ZERO bar read ISSUE 05 01 The bar code reader returned an Make sure tha Make sure tha count setting incorrect mark not seen error Incorrectly printed document Documents out of order Code not seen Check clean and adjust scanner Check digit in code is wrong Code not seen Check clean and adjust scanner Documents in xceeded th Page out of sequence Incorrectly printed document Documents out of order Code not seen Check clean a
151. illips head screws holding T plate in place remove T plate Left side Guide plate N 2 snap rings INSTALLATION SECTION G PAGE 2 Inser T plate igure Right side Guide plate Suction cup G 3 REMOVE SINGULATOR FINGER NOTE View of Sing Finger is from opposite side of inserter 1 Cycle the inserter so that the gripper arm is at its furthest point from hopper area 2 Loosen singulator finger then rotate it away from hopper and to right 3 Remove suction cup Loosen the cup mount and swing it down away from the hopper area Do not tighten yet 4 Jog the inserter slowly through one cycle observing mount closely You will notice that as the mount swings downward it will bottom against the shaft behind it If it does not swing mount further down and cycle the inserter again Singulator Finger Figure 438 SERVICE MANUAL ISSUE 05 01 G 4 438 INTERFACE COUPLING The machine is designed to permit the operator to connect the 438 directly to the inserting device The output is conveyed to the inserting device by an articulated conveyor arm The arm places the document directly in position for the inserter s gripper arm to pull the document out of the conveying arm and place it directly onto the track of the inserter Orientation As viewed from operator area of inserter 1 Gain access to shafts located under cover to the right of station 1 at table height 2 Jog inserter so gripper arms are m
152. ined PM Divt Mark Usage It is interpreted as a binary number This number must be constant Postal Meter Divert Mark for allthe pages within a package This number should sequentially increment from package to package when sequentially counting sheets upward This number sequentially counts from 0 to 15 Page Seq Mark Purpose Identify each individual page within a package The sequential incrementing of the number ensures the documents are assembled in the proper order Usage It is interpreted as a binary number This number sequentially counts from one to as high as seven Inserts Mark Gate Mark Location First OMR mark within a bank always present Purpose Indicates the start of an OMR code Usage synchronizes the OMR system to interpret the remaining OMR marks in the code Total Marks EOG Mark Purpose Controls the size of dynamic packages by indicating the end of a group Usage A solid bar is placed in this location on the page with the largest page ID number All other pages within a group should have no mark in this area Not EOG Mark 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION A PAGE 37 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION A PAGE 38 Parity Mark not available at this time Purpose Adds parity error checking to the code Usage This location is used to maintain an even number of solid marks within a code Note The fields that are marked
153. input opto 0 2 opto module 2 on opto rack 0 Does LED light when encoder operates Y Replace the input opto module and repeat the test Does the LED illuminate Check the wiring between the feeder speed encoder and the opto rack Check the pico fuse of the opto module Replace if required does this correct problem Check the encoder Replace encoder Check a different input to ensure the audible signal on the display is working Fix or replace display board Check connections between opto rack and CPU 486 If bad does correction fix problem Troubleshoot or replace the CPU 486 PWB e e REPAIR CHECKOUT PROCEDURE FOR EXTRA PAGE FED Clear any paper that was jammed in the machine and remove any obstructions Are mechanical settings correctly made Y Check the wiring and connections for intermittent connections Adjust the singulator roller Adjust the auxiliary feed belts Adjust the Paper Level Detector Adjust the Creeping Conveyor Check that the paper guides ensure that the paper passes under the sensor Check that the 438 is set up to run the length of stock that is being used Are the lights on the Feed Sensor illuminated Y N Go to step 4 Place one sheet of the current stock under the feed sensor and adjust the sensor so that the red LED goes out with the v sheet blocking the sensor Check that printing on the stock is not interfering with the sensor Does
154. ion K l 45 added item 52 l 47 added item 41 changed item 15 l 49 added item 55 J added MB Accumulator section K added MB Folder section Added replacement for 186 2823500088 as 118 30307 600 8 19 2009 438 SERVICE MANUAL ISSUE 05 01 071 26938 400 B COVER COVER 4 SECTION ISSUE DATES 05 01 Sect 05 01 Sect 05 01 Sect D 05 01 Sect 05 01 Sect F 05 01 Sect 05 01 Sect H 05 01 05 01 Sect J 05 01 Sect K 05 01 438 SERVICE MANUAL 071 26938 400 B ISSUE 05 01 COVER 7 SECTION INTRODUCTION SECTION A 1 REQUIRED 2 INTRODUCTION TO THE MANUAL ssmesnoensnnennznnennennonennennennennes 2 A 3 INTRODUCTION TO THE MACHINE eee 2 Ada FEEDERSEETJON i i perna up bg 2 A 3b ACCUMULATOR 2 2 22 22444 24 0 1000000 0000000 6 A 3c FOLDER SECTION 7 A 3d POWER ee terreno 8 A3e a EXIT CONVEY ORS 9 A 3f EMERGENCY STOP INTERLOCKS eee 9 A 4 MACHINE SPECIFICATIONS eese 11 5 RUN SCREEN 1 2 13 6 KEYBOARD OPERATION ssesnnonennzensonennzensensennensensensensensensensenses 14 EMERGENCY STOP
155. ired at the lead edge of the Gate mark 0 332 Clear area required at the trail edge of the code 0 166 438 HD SERVICE MANUAL 071 26938 400 ISSUE 05 01 Code location on paper Measured from the leading edge of the form the code should be placed on the first 1 3 of the form The Gate mark registration must be held to 1 print line 0 125 with 1 8 line spacing 0 166 with 1 6 line spacing The minimum distance of the Gate Mark from the leading edge is 0 25 All other marks should be placed with respect to the Gate mark within a 1 4 of a print line of their expected placement INSTALLATION SECTION A PAGE 43 438 HD SERVICE MANUAL 071 26938 400 9 LASER BAR CODE READ OPTION Laser Safety To prevent possible exposure to laser light that may exceed the CDRH s Accessible Emission Limit for a Class Il laser Your Model 30 has Scanning Safeguard feature a Laser Shutoff Flip Panel It shuts off the laser power if the mirror wheel fails to rotate which ensures that a stationary laser beam cannot exit the scan head This is a required feature and it should not be tampered with Use only in case of an emergency The radiation level from the laser does not constitute a health hazard Exercise care to avoid any unnecessary direct exposure to the eyes Avoid staring at the light source since prolonged exposure could result in eye damage Avoid deliberate eye exposure to the beam Inadvertent contact ho
156. ith no read Reader Type GBR 8 NA GBR 16 NA Line Bar Fixed packs See Package Size Exit Conveyor Type e Inserter Online By demand See Inserter Setup 1 for Open or Gripper setup e Inserter Offline Selecting this allows the inserter to run independent of the 438 without physically detaching e Hopper Fill Select HOPPER FILL when the inserter will be taking the folded documents from a hopper With or without demand See Eng Value 20 With no Inserter e Conveyor with or without demand See Eng Value 20 With no Transfer Conveyor Xcvy Exit at Folder with Folder Exit Sensor INSTALLATION SECTION PAGE 15 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION A PAGE 16 Use when Timed is selected 7 e Higher the number the larger the gap between sheets Double Detect Enable e Select to have the 438 detect double feeds Deselect if paper stock is causing false double detects Pulse Feed e Deselect to engage clutch for the entire pack AKA Stream Feed e When selected the feeder will place a larger gap between the sheets Page End e Clutch is off at lead edge of page on again at trail edge of page Timed e Pulse Feed Time must be set when using this option e Clutch is off at lead edge of page on after Time for Timed Read e Clutch is off at lead edge of page on after read received Pulse Feed Time 7 Accumulat
157. ll interrupt power to the conveyors and folder whenever a cover is opened Under the cover located 438 HD SERVICE MANUAL 071 26938 400 ISSUE 05 01 over the singulator mechanism e Under the cover located over the accumulator section e top cover of the folder Onthe lower cover over the 2 buckle plate folder and transfer conveyor meeting point interrupts power when the transfer conveyor is removed e clear lexan cover of the transfer conveyor INTRODUCTION SECTION A PAGE 9 438 HD SERVICE MANUAL ISSUE 05 01 INTRODUCTION 071 26938 400 SECTION A PAGE 10 4 MACHINE SPECIFICATIONS Listed below are specifications for the 438 Throughput Speed Max 30 000 documents per hour Material Paper Weights 20 75 GSM to 24 90 GSM Inquire for heavier weights Paper Size 7 x 7 178 mm x 178 mm to 11 x 14 305 mm x 356 mm Fold Types Z V amp DOUBLE V 24 Lb Stock 250 300 Gurley Stiffness Units Cross Grain Stiffness 20 Lb Stock 8 125 Gurley Stiffness Units 24 Lb Stock 12 150 Stiffness Units Moisture Content 4 6 by Weight Components Feeder Bottom feed top loading for continuous operation Optical Reader Optical code reading for group batch recognition sequencing and double printing control of 1 to 5 document groups Larger group batch setting available upon request Folder 4 plates Group selector Manu
158. n orientation or type of bar code changes Wat 2 The GBR 438 with the Accu Sort Model 30 uses the 3 of 9 code or Code 39 fixed or variable length This was the first code developed that used both numbers and upper case letters It is the most recognized and widely used for non retail applications Each character is represented by a stand alone group of 5 bars and 4 spaces The basic code set includes 0 9 A Z which is used for the start and stop characters and six other symbols and 438 HD SERVICE MANUAL 071 26938 400 ISSUE 05 01 96 for a total of 43 characters Because each of the characters are discrete and self checking Code 39 provides a high level of data security The Model 30 automatically checks all data for this symbology The bar code width must not be printed smaller than 0 010 025 mm Recommended width is 0 015 code height is 3 8 inch Minimum quiet zone start and end of 25 inches Bar coding sizing tolerance ratio tolerance per ANSI MH10 8 1983 Print quality must meet or exceed ANSI Grade B per ANSI X3 182 BAR CODE PRINT QUALITY GUIDELINE A 9c Adjusting Your Model 30 Scanner Your scanner can be mounted in any direction depending on the scheme of your bar codes Ladder orientation refers to a bar code whose bars look like a ladder when facing the bar code s direction of travel Picket Fence appear as a picket fence when facing the direction of travel Regardless of the direction of tra
159. nce sensor to start the next pack feed Higher is safer lower is faster but assumes pack leaves Accumulator Advance Feed OFF Time msec from pack movement at the detected at the Accumulator presence sensor to start the next pack feed 03 60 60 Bar Read Time Time msec waiting for reader response 04 300 250 Folder Exit Time Time msec allowed for pack to reach the folder exit sensor 05 150 150 Line Read Time Time msec waiting for reader response 06 10 10 Xcvy Dump To Acc Dump Time Time msec from Xcvy is going to move until next Accum dump is started 07 105 100 Xcvy Clutch On Time Time msec Xcvy clutch is on adjusted for number of stations Adjust up down to place the last pack at the Xcvy exit 08 225 200 Xcvy Into Station 1 Time 09 60 50 Xcvy Outof Station 1 Time 10 350 400 Folder Start To Conveyor Time 438 SERVICE MANUAL ISSUE 05 01 MISCELLANEOUS SECTION H PAGE 3 438 SERVICE MANUAL 11 12 13 14 15 16 17 18 19 20 21 150 10 20000 200 150 10 20000 215 ISSUE 05 01 MISCELLANEOUS SECTION H PAGE 4 e Should be greater than Eng Value 04 Folder Exit Time when Exit Type is Conveyor and not in test Test Console Switch 1 lt off diagnostics only used in debug mode Language Select e 1 English Xcvy Package InOut Counter e Number of packages expected in Xcvy 0 disables this check Acc Dump Clutch On Time e Constant value Accumul
160. nd adjust scanner PROBLEM ANALYSIS SECTION PAGE 20 The reader did not return a reading in the proper amount of time Make sure that the barcode reader is lined up with the code Make sure that the barcode print on the paper is good quality the barcode reader is lined up with the code the barcode print on the paper is good quality Incorrect page count in accumulator max sheets expected C 3g 17xxx Inserter Messages Error Description C 3h 19xxx EngValue Messages Error Description 20 COMMPORTS Messages Error Description C 3j 21xxx InFeed Error Description 21801 Paper Demand Timeout EVENT Paper Demand Switch ON to Paper Demand Switch OFF EVENT CHECK PaperDemandTimer CHECK VALUE 20000 msec ADJUST VALUE Engin Value 17 ANALYSIS Time exceeded 438 SERVICE MANUAL ISSUE 05 01 PROBLEM ANALYSIS SECTION C PAGE 21 SECTION REPAIR INFORMATION D 6e Package overhang at last station 42 D 6f Transfer conveyor s outfeed guides 42 D 6h Transfer conveyor package spacing problem 43 MAG cx 1 D 7 POWER UNIT 43 D 1 INITIAL ACTIONS eere 2 Dla Procede 2 2 16 List of Repair Checkout Procedures 3 D 1c Systems CHECKS en ete peer 4
161. nd is raised just above the main feed belt The auxiliary feed belts assist the main feed belt when variations in frictional quality Auxiliary Feed Belt Adjustment e The auxiliarv feed belts are adjustable bv angling the back end up or down AUXILIARY FEED Se P x cem E lI are encountered and the feeding of paper becomes Cr erratic The auxiliarv feed belts OT VAN FEED BELT would be adjusted when the gap between the fed sheets needs to be altered Raising the auxiliary feed belts will decrease the gap lowering the belts will increase the gap MAIN FEED BELT ADJUSTMENT KNOB Feed Belts Figure Sensor Adjustments All
162. ng Match in set Must change each set Same ID Match in set No change needed Blank Step NA None Min 0 to 1 Max 0 to 99999 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION A PAGE 47 438 HD SERVICE MANUAL ISSUE 05 01 071 26938 400 Bit Direction e Normal Count bits 5 to 1 left to right bit position 4 to 0 follow standard bit position of character Reverse Count bits 1 to 5 left to right bit position 4 to 0 B amp H e Normal A For multiple character numeric values For 5 numeric characters converted to a number bit positions 16 to 1 1 2 4 8 16 32 64 128 256 512 1024 2048 4096 8192 16384 32768 e Reverse A For multiple character numeric values For 5 numeric characters converted to a number bit positions 1 to 16 1 2 4 8 16 32 64 128 256 512 1024 2048 4096 8192 16384 32768 Bit Number Establishes the maximum number of bits in one character This is determined by the type of code being used Select from 5 through 8 5 3 of 9 Bar Code 6 8 not used at this time INSTALLATION SECTION A PAGE 48 Bar Read Setup 2 Inserts Code e Start 0 to 30 Start character e Length 0 to 20 Number of characters Start Bit 0 to 30 Starting bit position within character e Length_Bit 0 to 30 Number of bits Demand Feed Code Start Oto 30 Start character e Length 0 to 20 Number of characters Used with Normal A or Reverse A multiple charact
163. ng up the 438 the operator must remove any packages in the accumulator to be sure there will be no initial error conditions Solutions to Less Common Errors rare but more difficult to find problem can occur with shorts in the 24VDC circuit Intermittent failure of sensors 5VDC supply can result from the 24VDC short The short will only occur when a 24V component activates dropping the 5V supply across the line The 24V solenoid may be located some distance from the sensor which is the apparent problem consider what is supposed to happen before or as the sensor is supposed to read If either the Feeder speed or Folder speed are approximately half of the other an encoder channel is probably lost Check speeds through Test menu on display 438 SERVICE MANUAL ISSUE 05 01 Any time a new CPU 486 board is installed the presets must be reset or there will be an error displayed If PWB errors occur errors with PWB as probable source pull the board and make sure that all board components are properly seated Re install the board and make sure it is properly seated If reader problems are recurring re calibrate with the calibration sheet Feed the sheet through several times to ensure that the reader encoder is returning good data If data is inconsistent replace the reader encoder An invalid calibration error indicates that the calibration reading was more than 1596 different from the expected stored result See abo
164. nsor located on either the left or right feeder side rails A reader logic board interprets variation in light intensity as it is reflected off the paper and code marks INTRODUCTION SECTION A PAGE 5 438 HD SERVICE MANUAL ISSUE 05 01 INTRODUCTION 071 26938 400 SECTION 6 A 3b ACCUMULATOR SECTION The accumulator is fed paper from the singulator assembling groups of one to seven documents When the document oo package is complete it is fed to the folder Stacking Ramps Stacking Ramps the plastic wedges which position successive pages of a document package in order Stacking Rollers These are used to stop the paper and hold it in position When released the Stacking Rollers drive the collected pages out of the accumulator 2550 Dump Brake EE This prohibits the rollers from releasing paper from the accumulator Dump Clutch This activates the stacking rollers releasing the accumulated pages Accumulator Sensor LR re
165. old 4 0 4 0 8 accordion fold 74 1 105 1 2 75 2 106 3 76 3 107 4 0 4 0 55 8 05 For accordion folds fold plate stops should be set so they increase 1 mm from one fold plate to the next SECTION D PAGE 33 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 34 Setting Guide for Common Types of Fold 0 55 Setting the Fold Roller Gap Each folder is equipped with a paper thickness measuring device 1 Before setting the fold roller gap clamp the respective paper between the rollers and read the paper thickness of the scale The fold roller gap is set by means of setting screws which are numbered Roller 1 is the feed roller Roller 2 makes the 1 fold Roller 3 makes the 2 fold Roller 4 makes the 3 fold Roller 5 makes the 4 fold Roller 6 makes the 5 fold Roller 7 makes the 6 fold Roller 8 is the delivery shaft This layout shows a fold unit with 6 fold plates Rollers 6 and 7 are not part of fold units with 4 fold plates The delivery shaft would then be number 6 Rollers 4 5 6 and 7 are not part of fold units with 2 fold plates The delivery shaft would then be number 4 The basic principle of buckle plate folding has to be considered when choosing the correct setting of the fold rollers There are two different types of fold Folds with always symmetrical panels Folds with partly asymmetrical panels F
166. olds with always symmetrical panels If the panels of a folded sheet always have the same length when passing through the fold rollers the gap to be set for the respective fold roller depends on the number of paper layers which have left the preceding fold plate Folds with partly asymmetrical panels If the panels of a folded sheet are of unequal length when passing through the fold rollers accordian fold letter fold in fold plates 1 and 2 the gap to be set is governed by the number of paper layers contained on the longer panel 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 35 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 36 0 5 Fine Adjustments Corrections Fold Length Fold variations may occur if the fold plate stops are not set accurately of if the folding speed is changed The fold is off across the whole width of the sheets as opposed to a skewed fold Corrections of the fold length are made by turning the fine adjustment knob 1 A change in the folding speed also changes the fold length Therefore the set up speed must be maintained Skewed Folds Skewed out of square folds occur when the paper is fed not at the right angles with respect to the fold rollers This be corrected as follows e Mark the leading edge of a sheet and feed it through the fold unit 2 e To make the deviation more obvious exaggerate the skewed fold by hand 3
167. or Leave selected not functional at this time 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION PAGE 17 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION A PAGE 18 7 Folder Cvyr Transfer Folder Enable Xfer Conveyor Enable e Leave selected not functional at this time e Leave selected not functional at this time A 7g Infeed A 7h Line Read Setup 0 Select the type of infeed Note Refer to Section 8 for an explanation of GBR Line Code Read Off Setup 1 Refer to Section A 8c Creeper Setup 2 Refer to Section 8 Select when using the standard 2000 sheet creeper conveyor Setup 3 Refer to Section A 8c u on Setup 4 Refer to Section A 8c 470 type bulk loader with on off control by software monitoring the Select Line Read Cutter NA B amp H Read GBR Read 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION A PAGE 19 438 HD SERVICE MANUAL ISSUE 05 01 INSTALLATION 071 26938 400 SECTION A PAGE 20 Bar Read Setup e Encoder Updated as Inserter runs Refer to Section A 9d for setup information e Event List A 7j Inserter Up fms Sta PA 5 00 4 00 3 04 2 00 1 00 fi Mel Setup 1 2 3 Inserter Enable Degrees Encoder Updated as Inserter runs 438 HD SERVICE MANUAL
168. or or optical mark reader This sensor uses a reflective beam to generate an electric signal to a reader logic board The reader logic board interprets variation in light intensity as it is reflected off the paper and code marks Paper feeding is accomplished when the feed motor drives the belts An electric clutch engages the feed belt at a signal from the controller The optical encoder blue clad located on the right side of the upper pullout shaft monitors feeder run speed D 2b Timing Procedures Not applicable timing is a function of software and CPU 486 REPAIR INFORMATION SECTION D PAGE 5 438 SERVICE MANUAL ISSUE 05 01 D 2c Feeder Setup and Adjustments Paper Guide Rails These rails guide the paper from the Hopper Table through the singulator area and to the accumulator area without skewing The rails are divided into three sections on each side These are the accumulator feeder and hopper sections The singulator and hopper rails should be set so that with a single sheet of paper between them there is a 1 16 inch space between the side of the sheet and the guide rail Make certain that the guide rails run parallel with the side frame of the machine The singulator rails should be set first They are mounted on two black metal blocks which are mounted on cross shafts To adjust these rails loosen the set screws locking the singulator rail blocks to the cross shafts The hopper rails interlock with the sing
169. or comprises two black rubber belts driven by a motor located on the bottom side of the hopper Controlled by a paper level detector the motor is activated when the detector indicates that paper is low ISSUE 05 01 INTRODUCTION SECTION 2 Hopper Feeder Paper Guide Rails The two stainless steel rails mounted on the hopper are adjustable via a locking handle at the rear At the front they interlock with the feeder side rails then lock to shafts running across the machine Both sets of rails should be adjusted together Paper Hopper The Paper Hopper supplies the bottom fed friction feeder continuously while the operator loads paper from the top It has 4 mounts 2 each side with set screws in which the hopper slides The Hopper Table is located behind the feeder Paper level in the hopper is controlled by a demand switch The position of the hopper table determines how well the demand switch will perform this function During normal operation a metal wand rests on the incoming paper As more paper is needed the metal wand will fall low enough to close the demand switch This activates the creeper conveyor motor to drive the hopper belts conveying paper into the feeder area under the paper level detector When the proper level of paper is attained the wand will have been lifted enough to open the switch shutting off the creeper conveyor motor CONVEYOR DISPLAY
170. oving towards insert stations stop when vertical Gripper Arms Orientation to 438 Figure INSTALLATION SECTION G PAGE 3 438 SERVICE MANUAL ISSUE 05 01 INSTALLATION SECTION G PAGE 4 3 Install switch block on small shaft with the switch to the top rear Looking end on block should have 5 degree tilt towards other shaft If shaft is not long enough use AAA universal bracket on outer frame cover or deck Magnetic Block Figure 6 You are now in the input output test section Connect demand switch to the provided cable from the 438 output conveyor 7 Jog inserter to rotate magnet block assembly Desired timing is when the demand input 438 display goes on when the grip arm is one insert from output conveyor while moving away adjust position of magnet block to Switch Block and Bracket Figure accomplish this When satisfied with the timing tighten all set screws 4 Install double magnet block on large shaft NOTE Do not tighten yet snug one screw 5 Turn on the 438 press Test and then I O 144 Board refer to Section C 1 for the demand switch input location 6 5 BUHRS INSERTER INTERFACE OPTION This option kit provides a signal that synchronizes the 438 with Buhrs Inserter See Parts Section for a view of this assembly with part numbers 438 SERVICE MANUAL ISSUE 05 01 INSTALLATION SECTION G PAGE 5 SECTION MISCELLANEOUS SECTION H MISCELLANEOUS
171. peration Check for failure on the CPU replace as necessary Bad UARTs Bad software Check read setup again particularly focus Check for correct feed speed Check speed sensor for proper operation Check for failure on the CPU replace as necessary UARTs Bad software The page that was just fed did not follow the sequencing pattern If the page is not out of sequence check to see that the proper barcode is printed on the page and that the barcode matches the specifications Check to see that the proper barcode job is selected selected page Group is not part of set Check to see that the proper barcode is printed on the page and that the barcode matches the specifications Check to see that the proper barcode job is selected Check read setup again particularly focus Check for correct feed speed Check speed sensor for proper operation Check for failure on the CPU replace as necessary UARTs Bad software K K K K If page sequencing up the software expects the first page of each set to be either a 0 or 1 depending on what minimum page number was selected in the page setup If the page was page 1 check to see that the proper barcode is printed on the page and that the barcode matches the specifications Check to see that the proper barcode job is selected Group code was not in specified range i e 0 7
172. peration Check for failure on the CPU replace as necessary Bad UARTs Bad software Short Group error Y N N Check the page to determine if error is valid Is the problem corrected by any of the following tests Check read setup again particularly focus Check for correct feed speed Check speed sensor for proper operation Check for failure on the CPU replace as necessary Bad UARTs Bad software Duplicate Page error Y Is the problem corrected by any of the following tests e Check read setup again particularly focus e Check for correct feed speed Check speed sensor for proper operation N Check for failure on the CPU replace as necessary Bad UARTs Bad software Out of Seq error Y N Is the problem corrected by any of the following tests Check read setup again particularly focus e Check for correct feed speed Check speed sensor for proper operation N Check for failure on the CPU replace as necessary e Bad UARTs Bad software Invalid Group error Y N Is the problem corrected by any of the following tests Check read setup again particularly focus Check for correct feed speed Check speed sensor for proper operation N Check for failure on the CPU replace as necessary Bad UARTs Bad software 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 23 438 SERVICE MANUAL ISSUE 05 01 REPAI
173. pin in line ribbon cable header 438 SERVICE MANUAL D 6d 438 configuration of Exit sensor module The Exit sensor amplifier module on the Transfer conveyor has an active state selection switch on it This switch can set to LIGHT ON or LIGHT OFF The proper position for the switch is LIGHT ON NOTE This active state setting is the opposite to most of the other sensor modules on the 438 ISSUE 05 01 SENSOR MODULE Transfer Conveyor Exit Sensor Figure REPAIR INFORMATION SECTION D PAGE 41 EXT SENSOR 438 SERVICE MANUAL D 6e Package overhang at last station When a package is being presented to the gripper arm last station of the Transfer conveyor the package should have only the trailing edge of the folded document held by the flat green belts Positioning the trailing edge of the document at the centerline of the lower forward most shaft accomplished the desired document position When the gripper arm removes a package from the Transfer conveyor the flat green belts of the Transfer conveyor will creep if more than 3 4 of inch of the package is being pinched by the flat green belts The creeping of the flat green belts will cause the packages to become improperly gapped in the Transfer conveyor RAILING EDGE Or DOCUMENI CENTERLINI
174. proximately 3 4 from present setting Pass an alcohol dampened rag under the bottom of the singulator roller Be sure that it is making sufficient contact to clean away all dirt and debris from the contact portion of the singulator roller B2 b LUBRICATION No lubrication is required on the 438 NOTE If a mechanical component is out of line or deformed small amount of oil may be used as a short term fix to eliminate noise or binding until the component can be replaced SECTION PROBLEM ANALYSIS SECTION PROBLEM ANALYSIS 1 TEST SCREEN 2 Speed 2 Touch Setup cete tte Pot ette EO DR T HU OR HO RR 2 Test at p e ts 2 10 144 Board Inputs and 3 C 2 GENERAL SOLUTIONS TO ERRORS ssessnosenennnsnnnsnnosnneensennoennes 6 Solutions to Less Common 7 G3 ERROR CODES 8 Coa CLEXXX EEE Biere 9 C 3b L2xXx ee e eger RES TE 10 ESC ob 3xxx Accumnmlator iir aa 12 T4xxx Polder nennen see einatmen 12 C 3e 15 Xfer Conveyor Xfer Cvyr seen 13 C 3f 16xxx or 18xxx Reader oo ccc eene 15 C 3g 17xxx Inserter
175. r using the small amount of play available to raise the side of the singulator that has the most tension 7 Tighten the 10 32 x 5 8 socket head screws loosened in step 5 8 Retest the tension of the two strips of paper by returning to step 3 438 SERVICE MANUAL ISSUE 05 01 Rotating Singulating Roller The Singulating Roller is the place where the highest frictional forces are created These frictional forces wear down the Singulating Roller This requires that the Singulating Roller be rotated approximately every 250 000 sheets fed depending on paper type and operator s adjustment of the singulator 1 Raise Singulating Roller off the auxiliary Singulating Rollers and belt 2 On left hand side of the Singulating Roller use a 5 64 Allen wrench to loosen the set screw which keeps the Singulating Roller from rotating Rotate the Singulating Roller to expose a new wear surface rotate about 1 4 inch The worn surface should be rotated forward This will prevent the worn surface from coming in contact with paper that is being fed into the singulation point REPAIR INFORMATION SECTION D PAGE 9 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 10 Turn the knob clockwise to lower the rear end of the auxiliary drive belts Turn the knob counterclockwise to raise the rear end of the belts The ideal setting for the auxiliary belts is when the back e
176. r amplifier is set for Dark ON correct if necessary Check the pico fuse of the opto module Replace the input opto module if necessary Is the problem corrected Y N Replace the CPU 486 PWB Setup and run the machine Run the machine Check the singulator setup Is the feeder providing paper to the singulator Y N Did the feed belt pulse three times attempting to feed paper Y N Initiate feed clutch output test Press ENTER to energize the clutch listen for click or feel for clutch motion Does the feed clutch engage Y N Check output opto 1 8 opto module 8 on opto rack 1 Does LED light when ENTER is pressed If LED does not illuminate replace the opto and repeat the test Check for 24VDC at clutch connection If 24 is not present replace the clutch Check clutch spacing preset for 005 and clutch surface If clutch is worn replace 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 19 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 20 REPAIR CHECKOUT PROCEDURE FOR TWO SHEET SENSOR 2 SHEET SENSOR REFER TO SECTION FEEDER SCHEMATIC Enter the TEST menu from the VIP display Select INPUT from the submenu and select 2 Sheet Sensor input Repeatedly block the 2 Sheet sensor with your hand or two sheets of paper As the sensor is blocked observe opto 0 16 opto module 16 on opto rack 0 Does the red LED illuminate each time the sensor is blocked and go out when t
177. ry corrupted Restart machine Actual lines of codes must match parity setting odd or even Bad code ISSUE 05 01 PROBLEM ANALYSIS SECTION C PAGE 17 438 SERVICE MANUAL nn020 nn021 nn022 nn023 nn024 nn025 nn026 nn027 nn028 ISSUE 05 01 PROBLEM ANALYSIS SECTION PAGE 18 computed in action REGISTRATION BADowr Linecode marks are out of tolerance or the spacing is inconsistent BAD ON CHIP 8501 RAM INVALID READER ERROR INVALID CAL SETUP NO BANK 2 GATE MARK computed in action CALIB OUT OF RANGE YES NO EOG ARE SAME ROLL PAGE OUT OF SEQUENCE UNEXPECTED RESPONSE Bad code Hardware failure on reader board Battery failed or battery jumper missing Bad CPU 186 board CPU does not understand reader Feed through calibration sheet several times to ensure that encoder is reading properly consistent read numbers Reader encoder bad Reader was expecting two sets of read code Reader set up improperly Code is physically missing Check to see that the proper barcode job is selected one was missing Calibration failed Check calibration sheet Check read setup again particularly focus Check for correct feed speed Check speed sensor for proper operation This error is only associated with European machines Check read setup again particularly focus Check for correct feed speed Check speed sensor for proper operation Che
178. s this roller may be orange or blue Feed Sensor and Double Detect Sensor added The amplifier is located on the machine side frame in the singulator area Optical Mark Reader removed from Optical Mark Reader or Read Sensor A 3b Add Sensor Module section A 3c Folder Drive Motor added and the upper and lower dump shafts on the accumulator A 3e Changed this section description to Exit Conveyors and added supporting material A 4 Loading Capacity changed to 1500 Group Selector changed to 1 to 7 sheets Updated electrical service specs A 7j added 775 Changed screen shot for Inserter Setup 2 amp 3 Added explanation for Open Feed Added Ink Marking is normally located at Station 7 Rewrote Postal Meter Section A 8a Added 1 10 spacing A 8c Added Press Cancel to void any changes made to this screen or OK to set the changes and return to the Line Read Setup 0 screen Changed Parity Mark to Not available at this time Added 1 10 option in Lines Inch Line Read Setup 2 Added 1 10 in two places in Calibration section Added set in Line Read Setup 3 Group Seq and Page Seq Min and Max In Line Read Setup 4 step 8 added If these values are not obtained go to section A 8b and reset the probe A 8d Removed Miscellaneous Problems section 438 SERVICE MANUAL ISSUE 05 01 COVER 071 26938 400 B 5 438 SERVICE MANUAL ISSUE 05 01 071 26938 400 B A 9d Rewrote Bit Number Adde
179. served GBR Systems Corporation Copyright protection claimed includes all forms or manner of copyrighted materials and information now allowed by statutory or judicial law or hereinafter granted including without limitation material generated from the software programs which are displayed on the screen such as styles templates icons screen displays looks etc Printed in the United States of America 438 SERVICE MANUAL ISSUE 05 01 COVER 071 26938 400 B Lore USING THE MANUAL 1 TABLE OF CONTENTS Each capitalized alphabetic character represents a major division within the manual Section A Under each major division the capital letter is followed by a number This represents a subdivision of the major section Section A1 is a subdivision of A Under each subdivision an alpha numeric combination is followed by a decimal and a lower case letter This represents a smaller division under a subdivision Section A 1a is a subdivision of A 1 Section A 1a1 is a subsection of A 1a Each major section of the manual begins with page 1 and is numbered in sequence through that section only Section A begins with page 1 section B begins with page 1 etc There are not necessarily any subdivisions beyond level 1 in a Parts Catalog This manual is divided into Section A through J A detailed table of contents is located on the first page of each section SECTIONA INTRODUCTION Machine Orientation Machine Specifications Run and Setup Screens Line
180. shafts and rollers and the upper and lower dump shafts on the accumulator Folder Speed Encoder An encoder located on the infeed roller shaft which provides a folder speed signal e Position 1 Oj Position 3 Position 2 ORC Position 4 Fold Rollers pa Rollers 438 HD SERVICE MANUAL ISSUE 05 01 071 26938 400 Folder Section Representation PS2 E n gy 1 UNE 4 LINE N 0 3 PSI NN INTRODUCTION SECTION A PAGE 7 438 HD SERVICE MANUAL ISSUE 05 01 071 26938 400 A 3d POWER UNIT The Power Unit is located inside the cabinet and consists of the following components Master Relay Electric safety interlock switch Fuses Fuse tips illuminate when the fuse is bad Solid State Relays SSR For switching high power items motors etc 5 VDC Power Supply logic power 12VDC and 12VDC power also logic power 24 VDC Power Supply power clutches etc deo Tov Power Unit Interior Figure INTRODUCTION SECTION A PAGE 8 EXIT CONVEYORS Straight Conveyor 52 Delivery This is an optional stand alone straight conveyor that enables the
181. sing paper LED off Input of lead edge detection sensor probe 2 sensing paper LED off Not used Input of selected line code sensor Probe 1 or Probe 2 PRINTED WIRING BOARDS SECTION E PAGE 7 ISSUE 05 01 PRINTED WIRING BOARDS 438 SERVICE MANUAL SECTION E PAGE 8 E 6 GBR TJ LINE CODE CARD E 7 B H READ CARD GBR Part Number 042 26622 500 GBR Part Number 186 330002717 This card is mounted separate from the Single Channel This card is physically mounted on the Single Channel Read Read Card but connected with cables Card Function Function e Read Sensor Light source analyzer Read Sensor Light source analyzer Read Signal amplifier Read Signal amplifier 812 O 042 25129 000 MADE IN USA
182. t Stations 6 Pulse Feed ON Number of Empty Stations 2 Type of Transfer OPEN FEED Encoder Type GBR 100 Tick Encoder Beep Bell ON Opto Logic Type AC DC Dumb Inserter Input Conveyor 2000 Sheet Conveyor Postal Meter 2 On at 200 for first Meter High Count Stop 07 inline 240 if second meter inline Performance Off Off at 010 Inserter Online Offline Online Insert Sta 07 First Page Hold delay 30 Pt 1 Config ID Xfer Conveyor W Inserter Postal Meter 3 On at 200 for first Meter Dump to Feed Delay Setup 05 inline 240 if second meter inline Dump Delay Timer Setup 25 Off at 010 Insert Sta 07 Pt 2 odi on Enable On at 100 Postal Meter Weights ee 00004 2 to 3 Envelope Hopper Vacuum On at 230 Insert Sta 2 Weight Page Envelope Page 00001 Envelope Read GBR Line 00001 gt 00001 gt 00001 gt Demand Feed 00001 Page sequence Weight Inserts 1 2 3 4 gt 00001 gt 00001 gt 00001 gt Group Sequence 00001 Ink Mark Weight Inserts 5 6 7 8 gt 00001 gt 00001 gt 00001 gt Postal Meter Divert 00001 Parity End of Subset Random Check Mark Blank Page Error Stop Number of Windows Window Setup Lines Per Inch Probe Weight Calibration Tolerance Code Field Format EOG Page Group Inserts Postal Meter Divert Subset Parity Random Check Mark 438 SERVICE MANUAL ISSUE 05 01 Normal Item Count Off Off Off Off 2 NO divert by mark and YES Meter 1 Weight None Off Off
183. ted See Section A7 for Setup Screens See Section C Problem Analysis for Test screens Run Test Press to enter diagnostic screens for more information refer to Section C Setup Press to enter setup screens for more information refer to Section A7 Release Brakes Releases Applies Accumulator and Feed Brakes to allow jam clearing Information Displayed 438 HD SERVICE MANUAL Revision Software and Build Date top line Packages Total package counter Reset in System Setup Also resets during bootup Sheet Displays the of sheets in the accumulator Package Rate Used to monitor throughput of the 438 Calculated at every pack dumped from accumulator not averaged Demand Rate Displays the package demand rate from the inserter Calculated at every demand signal transition not averaged Date and Time not functional at this time EOG Displays end of group ready for dump Group Page Insert Marks Control Marks Monitor Events Displays event history however entire list is lost when power is turned off 071 26938 400 ISSUE 05 01 GRE jalea Run 2412 024 20 Y gi MET 25 1 Don ral Bark Freier 224 Lom FREE 117121 Power p tina Lineheadrr Person DOLIO 35A 125 185 Frederi te yates TED ds i 0 27 oe Freir
184. the 438 Clean all accumulated paper dust from DO NOT ATTEMPT TO CLEAN THE 438 WHEN THE the electronic paper sensors MACHINE IS RUNNING ATTEMPTING TO DO SO COULD RESULT IN INJURY BE SURE THAT MACHINE POWER IS B2 a2 Cleaning the Fold Rollers OFF AT ALL TIMES WHEN CLEANING DO NOT USE ANY LIQUID ON THE FOLD ROLLERS The fold plates must be removed in order to clean all fold rollers For 438 SERVICE MANUAL ISSUE 05 01 PREVENTIVE MAINTENANCE SECTION B PAGE 1 438 SERVICE MANUAL more information on cleaning the fold rollers refer to your 438 Operator Manual B2 a3 Machine Cabinets and Covers Clean the machine cabinets and covers using a soft damp cloth B2 a4 Paper Hopper The feed belt should be cleaned with a substance such as isopropyl alcohol that does not leave a film some alcohol to a rag then lightly rub all dirt and film off of the belts B2 a5 Singulator The Singulator must be as clean as possible at all times to insure the proper feeding and singulation of paper by the feed belt This may be done first making sure that the singulator is not worn If so loosen the small set screw on the operator side and rotate the roller to a point where a rounded spot on the roller will contact the paper ISSUE 05 01 PREVENTIVE MAINTENANCE SECTION B PAGE 2 NOTE If there is no rounded spot available the singulator needs to be replaced immediately Once this is accomplished raise the singulator roller ap
185. the LED on opto 0 2 light when the sheet is under the sensor Y N Check the small fuse for opto relay 2 Check the optical relay Check wiring from the Control Box to the Display Check the wiring and connections for intermittent connections Is there 24 VDC between TB2 1 and TB2 2 Y N Check the connection from the controller to the Feeder Check the wiring e Check 24 VDC power supply Clean the sensors Do the LEDs come on Y N Replace the sensor 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 15 438 SERVICE MANUAL ISSUE 05 01 REPAIR INFORMATION SECTION D PAGE 16 REPAIR CHECKOUT PROCEDURE FOR PAPER JAM IN FEEDER Clean the sensors Do the LEDs come on Y N Check sensor connections Replace the sensor Clear the paper that was jammed in the machine and remove any obstructions Are mechanical settings correctly made Y N Check the wiring and connections for intermittent connections Adjust the singulator roller Adjust the auxiliary feed belts Adjust the creeping conveyor Check that the paper guides ensure that the paper passes under the sensor Ensure that the drive pulleys are tight Check the feed clutch 7 Check that the 438 is set up to run the length of stock that is being used Are the lights on the Feed Sensor amplifier illuminated Y N Enter diagnostic Routines Select Display status of Feed Sensor opto 0 0 Does display change to ON with the sensor blo
186. to the width of a solid bar 0 020 inch 0 003 and 1 4 to 3 8 inch long Rotating the read sensor while adjusting the focus will permit the image to be set parallel to the code block marks Set the light beam image parallel to the lines of the code block before tightening the read sensor locking screw Before leaving the read sensor adjustments make sure that the light beam is centered on the code block printed on the document Code block movement from side to side due to print quality or paper size ISSUE 05 01 INSTALLATION SECTION A PAGE 28 variations may cause the read sensor to see only partial code resulting in a read error READER MOUNT BRACKE LOCKING THUMBSCREW Read Probe Assembly Figure A 8c 438 Line Read Setup Screens Line Read Setup 1 Setup gt Line Read gt Setup 1 Systems Lime Read 1 438 HD SERVICE MANUAL 071 26938 400 ISSUE 05 01 DEMAND FEED NORMAL The machine will demand feed on the absence of an End Of Group mark This means the only page in a set that has the mark is the last one REVERSE The machine will demand feed on the presence of the End Of Group mark This means that all pages in the set will have the mark except the last one YES NO Used where all pages have a mark Each page will have an End of Group or a NOT End
187. ulator rails at one end They are locked into place at the rear of the machine when the rail locking shaft is in the locked position The accumulator area side rails do not actually guide the paper from side to side They should be set so that there is approximately 1 8 inch on either side of the sheet NOTE Be sure the side rails are feeding the paper parallel to the Singulating roller REPAIR INFORMATION SECTION D PAGE 6 Paper Hopper Adjustment The Guide Rails align the paper from the hopper table into the singulator This permits the paper to exit the singulator area in proper alignment with the transfer conveyor without skew The position of the hopper table relative to the feeder is a very critical adjustment To adjust the hopper table a Place a sheet of paper in the feed area up to but not under the singulator b Loosen the four set screws of the hopper guide rails Once this is accomplished the table will move freely in and out Do not pull the table all the way out of the clamps it will fall Bring the hopper table 1 2 away from the back edge of the sheet of paper d Tighten four set screws down to clamp the table into this position Whenever document length is changed this process must be performed to ensure the proper transfer of paper from the hopper table to the feeder area Paper Level Detector Setting Main Feed Belt Tension
188. ured After running one sheet go into Setup Line Read and compare the marks on the page in question to the 175 and 05 on the screen f more 15 appear on the screen than lines on the page go into Setup gt Line Read gt Setup 4 and increase OFFSET 2 by 1 volts 1 increment Repeat this step until a good read is obtained f more 05 appear on the screen than lines on the page Setup gt Line Read gt Setup 4 decrease OFFSET 2 by 1 volts 1 decrement Repeat this step until a good read is obtained f the correct number of 15 appear but they appear to have uniformly shifted up or down the page all the marks shift either a space or two up the page or a space or two down the page the gate mark is not being found properly Go to Setup gt Line Read gt Setup 3 and make sure that your read window is set up properly Remember the reader begins looking for the gate mark two lines before the start of your read window If you have a line1 4 above your gate mark say your Line Code Reader see Section A 8b SETTING UP THE GBR LINE mark is at line 15 on the page and you are set to 1 8 line spacing CODE READER unless you set your read window to start 1 line below your gate mark line 16 on the page the reader is going to catch the first line as your gate mark If the correct number of 175 appear but they seem to have shifted on the page there are not the proper
189. ut Feed Clutch 1 01 Output Folder Motor 1 02 Output Feed Motor 1 03 Output Master Relay 1 04 Output Separation Sol 7 inserter signal 1 05 Output Separation Sol 1 inserter signal 1 06 Output Separation Sol 8 inserter signal 1 07 Output Shingle Conveyor Motor 1 08 Output Separation Sol 2 inserter signal 1 09 Output Separation Sol 3 inserter signal 1 10 Output Separation Sol 4 inserter signal 1 11 Output Separation Sol 5 inserter signal 1 12 Output Separation Sol 6 inserter signal 1 13 Output Separation Sol Env inserter signal 1 14 Output Ink Mark Solenoid inserter signal 1 15 Output Env Flap Sns Dis inserter signal 1 16 Output Emergency Stop inserter signal 1 17 Output Insert Station 1 Error inserter signal 1 18 Output Paper Hopper Request 1 19 Output Postal Meter Divert inserter signal 1 20 Input Paper Demand Wand 1 21 Input Ins Run Lamp 1 22 Input Cutter Jam Sensor 1 23 Input Inserter Sta 1 Sns Rack 00 Not Used 01 Not Used 02 Not Used 03 Not Used 04 Not Used 05 Not Used 06 Not Used 07 Not Used 08 Not Used 09 Not Used 10 Not Used 11 Not Used 12 Not Used 13 Output First Hold Kicker 14 Output First Hold Brake 15 Output First Hold Clutch 16 Input Ins Ink Mark Pres IO ID IIO ID IO INO INO IO
190. ve PROBLEM ANALYSIS SECTION C PAGE 7 438 SERVICE MANUAL ISSUE 05 01 PROBLEM ANALYSIS SECTION PAGE 8 3 ERROR CODES Error A unique error number The first two digits specify a machine area or module The last three define the specific error EVENT The event or process being monitored EVENT CHECK The mechanism or thing used to monitor the event ERROR ON The reason an error is flagged CHECK VALUE The value being used to flag the error Some are calculated based on speed sheet length etc ADJUST VALUE Where the check value can be adjusted ERROR CODE SECTIONS 11xxx System Messages 12xxx Feeder Messages 13xxx Accumulator Messages 14xxx Folder Messages 15xxx Xfer Conveyor Messages 16xxx Barreader Messages 17xxx Inserter Messages 18xxx Linereader Messages 19xxx EngValue Messages 20xxx Messages 21 InFeed Messages 11 System Error Description 11820 Exit Demand Timeout EVENT Accum Package Ready to Exit Demand EVENT CHECK ExitDemandTimer CHECK VALUE 60 sec ADJUST VALUE Value 21 ANALYSIS Time exceeded 11821 Cover Interlock Open or Emergency Stop Set EVENT Interlock ON EVENT CHECK Interlock CHECK VALUE ADJUST VALUE ANALYSIS Interlock ON at power ON 11822 Cover Interlock Open or Emergency Stop Set EVENT Interlock ON EVENT CHECK Interlock CHECK VALUE ADJUST VALUE ANALYS
191. vel the scan line must be perpendicular to the bars In some applications codes are printed on glossy paper or covered with a shiny material such as cellophane When this happens it is possible that the code surface reflects so much laser light that it is very difficult for the scan head to decode the bar code To avoid reflections from the surface of glossy bar codes do not mount the scan head parallel with the object to be scanned Mount the scan head at a five to ten degree angle so the laser beam reaches the bar code at a slight angle INSTALLATION SECTION A PAGE 45 438 HD SERVICE MANUAL 071 26938 400 ISSUE 05 01 A 9d Setting the 438 to Read Laser Bar Code Setup gt Bar Read Modifications to the bar setups are retained as long as the bar job defaults are not restored or the internal non volatile storage is not overwritten by a new ini file or is lost INSTALLATION SECTION A PAGE 46 Job Select the job to run by pressing 7 or gt Note If your job is not listed go the next section Setup 1 to program it in Refer to the Appendix in this manual for setup parameters for various jobs If your job is not listed call the factory Start This will turn the laser on continuously to hand test the lasers positioning The screen will read BAR READ and an audible beep will sound when the laser reads the code The results of the read will be shown on the Screen Reset Job Defaults Sets th
192. wever is not a cause for alarm Any service should be performed so as not to violate compliance with the Code of Federal Regulations Title 21 Part 1040 Section 10 21 CFR 1040 10 as administered by the Center for Devices and Radiological Health a service of the Food and Drug Administration under the Department of Health and Human Services not attempt to defeat any safety provisions ISSUE 05 01 INSTALLATION SECTION A PAGE 44 COMPLIES WITH DHEW REGULATIONZI CFRSUBCHAPTER J DANGER LASER RADIATION WHEN OPEN a ti de AVOID DIRECT EXPOSURE MODEL 30 3 zu 144 Top View FLIP DOWN TO SHUT OFF LASER AVOID EXPOSURE LASER RADIATION EMITTED FROM THIS APERTURE u y DANGER y LASER LIGHT WHEN OPEN pa AVOIDDIRECT EXPOSURE TO BEAM a U USTED 8 Tus PROCESS AN Front View Side View Standard Laser Caution Labels Bar Code Basics A bar code is a group of rectangular bars and spaces arranged in a preset pattern The pattern is organized to represent elements of data referred to as characters The standard industry codes can represent several alphanumeric characters There are many different types of bar codes Each type uses its own symbology which defines how the bars and spaces represent the letters and numbers The figure below shows each part of a bar code The labels for each part remain the same even if the positio

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