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1. PIO p K lt lt 3 lt 1 lt 5 17 lt 6 7 2 c 59 e 2 i 4 00 vo B 5 MODUL MODU MODULE MODULE MODUL MODUL KODULE 4 ORT 5 5 4 2 y S sit 4 2 a A A Box ifsa lt 16 10N 3 e lt 18 lt 19 en 2 152 K EKI d 5825 lt lt lt lt lt lt lt ON ADAPTER 2 n EPOR 2 D 17807 TO INSERTER CONNECTOR PIN 30 lt TO INSERTER CONNECTOR PIN 33 EMERGENCY REFERENCE 30 5 cn 45 FOLDER 1 0 BOARD MODULE 2 OLDER SPEED ENCODER G m SENSOR SENSOR FE S p Mb 3 24V RETURN REF NOTE 7 b pg INTERNATIONAL COLOR i gt B PE DES FOR SNS KI pe Ly 1 8K lt 5 2 88 A lt 6 3 BU 24 gt 27 A ridi 8 5 lt 7 AUX Y 9 53 lt 9 REF NOTE Bee z en en YEL 0 13 en E lt u N 25 en 2 8 Cn 1 H 2 25 3 BU
2. 002D 17812 11 TRANSPORT CONVEYOR PAGE 2 INDEX PART NUMBER 1 002B 08408 2 002A 17309 3 002A 18044 4 002B 18366 5 002B 19599 002B 08409 600B 18635 6 002A 19600 7 014 91264 249 8 019 200037 9 112 S6A320H3712 10 112 S6A320NF037 11 113 200230037 12 126 SC37 13 016 S0375062512 14 153 FB683 15 158 S3PPB5ST 16 600A 16349 031 17 600A 16349 034 18 600A 17224 19 600B 18645 20 600B 18650 SMART FEEDER SERVICE MANUAL DESCRIPTION BRAKE IDLER ROLLER PULLEY CONVEYOR DOCKING PORT CLUTCH SHAFT ASSEMBLY CLUTCH ONLY SHAFT ONLY HOOK ASSEMBLY SHOULDER BOLT E RING PULLEY TIMING 20T PULLEY TIMING 20T BELT TIMING SET SCREW COLLAR SHIM FLANGE BEARING RADIAL BEARING GEAR PLASTIC SPUR HUB CLAMP DRIVE ROLLER NIP WHEEL PIVOT BAR UPPER DRIVE SHAFT ISSUE 12 00 600B 17689 600B 18648 600B 18649 600A 17697 600A 17700 600C 17708 600C 17709 600D 17724 600A 17735 600B 17743 600B 17744 600B 17745 600A 17742 600B 17746 600B 17747 600B 18640 600A 17785 600B 17888 600D 18035 600B 18643 NIP ROLLE
3. 002K 21390 FIRST PAGE HOLD KIT INDEX PART NUMBER 002 07746 002 08414 014 10251120 016 0375062501 020 01020632 057 E32CC200 163 EUT061201 188 231 WW 600A 16349 034 600A 18200 600A 18704 600A 20796 600B 16349 027 600B 19006 600B 20768 600B 20795 002D 07755 DESCRIPTION CLUTCH BRAKE SHSS 10 32 X 1 25 SHIM 01 THICK STANDOFF 10 32 X 2 SENSOR FIBERS THRUST BEARING REFLECTIVE TAPE HUB CLAMP CLUTCH STOP SPAN BLOCK BRAKE MOUNT SPUR GEAR C SENSOR BRACKET SHAFT RIGHT COVER SLIDE MOD FIRST PAGE HOLD CONTOL PANEL SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 71 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 72 002K 08133 775 LEFT HAND 6 STATION INSERTER KIT L STATION CONTRO lt gt CONTROL N M T AUXILIARY Ber N M 2 y dad
4. INDEX PART NUMBER DESCRIPTION SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 9 SMART FEEDER SERVICE MANUAL O 002 08076 002 08113 002 08505 002 08523 002 08524 002 08525 002 08537 002 08541 002 08106 0020 08138 0020 08152 0020 08543 020 RA025C0803 020 RN00620416 020 RN00620425 020 RN00820416 025 A218VN 026 ABMMA 026 PLM1M 030 SMODC5 030 SMIDC5 042 PB24SM 045 018135 045 222135 046 4285011B 051 0476350 173 VBM1062 600A 17923 600B 22454 600D 19050 002B 07725 002B 08002 CPU 186 BOARD P8 CABLE ASSEMBLY DISPLAY TO CPU 5V CABLE READER 5V CABLE CABLE 91 ASSEMBLY CABLE 90 ASSEMBLY P9 CABLE ASSEMBLY KEYBOARD CABLE SBX I O amp SECURITY KEY CARD INTERCONNECT BOARD ASM 8 SLOT CARD CAGE ASM ACCUMULATOR CABLE SPACER ROUND 187 LONG STANDOFF ROUND 1 LONG STANDOFF ROUND 6 32 X 1 56 STANDOFF ROUND 1 LONG RING LUG 8 TY WRAP ANCHOR TY WRAP MODULE RED MODULE WHITE I O BOARD PB24 SM WIRE 18 AWG GREEN WIRE 22 AWG GREEN CABLE RIBBON 28 GA 50 COND CAPACITOR 47uf 35V RUBBER MOUNT TERMINAL BLOCK OPTO RACK BAR PANEL ENCODER INTERRU
5. 5 i d C 11110 mm 1 A pom KO E 002D 17812 TRANSPORT CONVEYOR PAGE 2 INDEX PART NUMBER 1 002B 08408 2 002A 17309 3 002A 18044 4 002B 18366 5 002B 18850 002B 08409 600B 18620 6 002A 19600 7 014 91264 249 8 019 200037 9 112 S6A320H3712 10 112 S6A320NF037 11 113 200230037 12 126 SC37 13 152 B694 14 153 FB683 15 158 S3PPB5ST 16 600A 16349 031 17 600A 16349 034 18 600A 17224 19 600B 17683 20 600B 17688 SMART FEEDER SERVICE MANUAL DESCRIPTION BRAKE IDLER ROLLER PULLEY CONVEYOR DOCKING PORT CLUTCH SHAFT ASSEMBLY CLUTCH ONLY SHAFT ONLY HOOK ASSEMBLY SHOULDER BOLT E RING PULLEY TIMING 20T PULLEY TIMING 20T BELT TIMING SET SCREW COLLAR PLAIN BEARING FLANGE BEARING RADIAL BEARING GEAR PLASTIC SPUR HUB CLAMP DRIVE ROLLER NIP WHEEL PIVOT BAR UPPER DRIVE SHAFT ISSUE 12 00 600B 17689 600B 17691 600B 17693 600A 17697 600A 17700 600C 17708 600C 17709 600D 17724 600A 17735 600B 17743 600B 17744 600B 17745 600A 17742 600B 17746 600B 17747 600B 17780 600A 17785 600B 17888 600D 18035 600B 18621 NIP ROLLER IDLER SHAFT IDLER S
6. 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 logic power 5 12VDC and 12VDC power also logic power 6 24 VDC Power Supply power clutches etc C 3 _ i N N 7 KIA 1 N 4 M L 0 S PS I 500000 5 Power Unit Interior Figure A 5b SMART FEEDER SERVICE MANUAL ISSUE 09 00 INTRODUCTION 071 25287 400 SECTION A PAGE 11 SMART FEEDER SERVICE MANUAL 071 25287 400 SENSORS 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 an on the top 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 top Transfer Conveyor Sensors This monitors the discharge of paper packages from the output conveyor It acts to confirm the processing of specific documents Accumulator Sensor The Accumulator Sensor indicates presence o
7. TAA AAAA AAAA O AS IRING WONT S ST I OR TE CRON DINANE BEN 4 MATERIAL FNSH 8 WAS YE Daa ECN NO DESCRIPTION SCALE Y WAN 004 Ta SALE DEN 73 002K 08135 lt gt Bon NOTES FOR INSERTERS WITH MEER EUER IGTAIL WIRE COLOR DESCR
8. Turn the knob clockwise to lower the rear end of the belts would be adjusted when the gap between the fed auxiliary drive belts sheets needs to be altered Raising the auxiliary feed Turn the knob counterclockwise to raise the rear end belts will decrease the gap lowering the belts will of the belts increase the gap AUXILIARY FEED BELTS The ideal setting for the auxiliary belts is when the back end is raised TF just above the main Eod EL feed belt lt m q 1 E L man FEED BEL B N i N On 9 MAIN FEED BEL ADJUSTMENT KNOB Feed Belts Figure SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 11 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 12 D2 c7 Sensor Adjustments All of the paper detecting sensors on the 420 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
9. a 10 CARD CAGE e a 8 A ye UI X Iu o 5 o i u a KI i Anunnnnnnnnn p 1 MC ON NSERTER 002K 07970 AC DC INSERTER CONTROL OPTION INDEX PART NUMBER NOOR WD 10 11 12 13 14 15 SMART FEEDER SERVICE MANUAL 002A 07940 002B 07769 002B 08009 002B 08024 002B 08213 002B 20856 002C 07944 002C 07948 002C 07968 002 08132 0020 07972 030 SMIDC5 030 SMIDC5F 030 SMODC5 113 082150025 600A 20855 DESCRIPTION PLUG INSERTER DUMMY CABLE 9 POS ENCODER CABLE STATION 1 SENSOR SENSOR AMPLIFIER ENCODER amp MOUNT ASSEMBLY DC CABLE amp BOARD AC CABLE amp BOARD SENSOR INTERCONNECT CABLE INSERTER INTERCONNECT CABLE INTERCONNECT BOARD MODULE WHITE
10. 706 25697 400 T J LINE CODE READ OPTION INDEX PART NUMBER 1 002A 16457 004 2 002B 08126 3 002B 18518 4 007 25586 600 5 007 26925 600 6 007 26926 600 7 014 082511040 8 042 25272 500 9 042 26622 500 10 088 25588 500 11 192 50122302B 12 595 25585 600 13 595 25698 600 14 600A 18374 15 600A 18378 SMART FEEDER SERVICE MANUAL DESCRIPTION THUMBSCREW DUAL READ ENCODER CABLE ENCODER READ HEAD ADJUST BRACKET BRACKET MOUNT BRACKET READER SHSS 8 32 X 25 BRASS SINGLE CHANNEL READ BOARD GBR OMR SBX ASSEMBLY READ HEAD ASSEMBLY FIBER OPTIC READER PROBE SHAFT STUB SHAFT PULLEY BELT ISSUE 12 00 PARTS SECTION I PAGE 63 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 64 002K 08066 B amp H LINE CODE READER UN 19 AD ARA d gt T M 8 n 0 U mE I SECTION A SECTION 002K 08066 B amp H LINE CODE READER INDEX PART NUMBER DESCRIPTION 1 002B 08063 DUAL PROBE OUTPUT CABLE 2 002B 08126 DUAL REA
11. SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 11 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 12 002D 08135 POWER UNIT A C BOX INDEX PART NUMBER DESCRIPTION 1 002B 08521 METER ASSEMBLY 2 024 213406253 TERMINAL STRIP 3 030 1240D25 SOLID STATE RELAY 4 030 2KUMP14D182 RELAY SPDT 24VDC 5 031 24200 SOCKET RELAY 11 PIN 6 032 00005250 FUSE 1 2 AMP 7 032 00015250 FUSE 1 1 2 8 032 00030250 FUSE 3 9 032 00040250 FUSE 4 10 032 01120250 FUSE 12 11 032 00150250 FUSE 15 12 032 10020250 FUSE 2 13 035 H320B POWER INLET 14 037 60950 1 SOCKET CONNECTOR 15 039 67293001 CONNECTOR 16 039 88010641 RECEPTACLE 17 044 ECV24N48 24v POWER SUPPLY 18 044 VL30341010 5v POWER SUPPLY 19 050 24206 LINE FILTER 10 AMP 20 050 20R6 EMI FILTER 20 AMP 21 067 V130LAZOA VARISTOR 22 067 V33ZA5 VARISTOR 23 173 2192 BUMPER 24 600B 17246 BRACKET 25 600D 17897 COVER 26 600D 19051 PANEL ENCLOSURE 002E 19047 FEEDER ASSEMBLY PAGE 1 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION
12. f 5 FR x N N E Mg ES rii o E Lo Is NS NS o E gt 6 5 LEFT SIDE VIEW 002K 23756 INK MARKER OPTION BELL amp HOWELL INDEX PART NUMBER DESCRIPTION 1 002B 07186 INK MARKER INTERFACE CABLE 2 002B 07187 SENSOR INPUT MODULE 3 002B 07188 MODULE 9 INTERFACE CABLE 4 002B 23702 SENSOR ASSEMBLY 5 002C 07200 INK MARKER CONTROL BOX 6 007 24265 600 HOLD DOWN BRACKET SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 75 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 76 389 26066 400 INK MARKER KIT ES 7 2 2 1 n s 0 N B 0 N El ols I 0 2 j NI 5 Ree fs L _
13. LEFT 077 un WOW 1 gt 1 TD TE 2 2 rimi 2 d Te p 0 sar 2 tre ars c E f E 29 T TH i lt lt 32 814 E ura bv m t E 50 TAI s t 9 RAY TE 5 t E mn tE wo 3 t c 3 7 PETIT 4 22 0 mm SX t E T 4 S TT ow 5 T wa lt Dm t a t E E TX 2 tre E ESE 9 lt 314 ED mm lt mE m WE lt gt warmen Es WOME NEE nz Em lt TY y BE lt Em KE lt MITI lt lt Sy 810 wu 1 p Uo mom t lt ETT 4 te a 5 b o lt 42 306 mon ET wa lt m S 5 ET EE t PEG MINES 5 lt ana EI EN E a 0 25 z 0 f mim en TE gt y tire lt 312 ET oms Is sen 6 TH E lt 3 rr DT t E zl 0 En DOCU mm 5 tire tae T lt lt posing XX xong INTERRUPT MINOR 1 HEARTBEN RESET ADI LT ATA AAA w KARRARAL v
14. A TERMINAL READY CLEAR TO SEND SIG GND MM kadda a adada adadai ia di o db dh f dh dh dd JUMPERS B 0000000000 ER FROM CARD 08
15. 14 RE FOR FEEDER MOTOR 16 RE FOR FEEDER SPEED ENCODER 17 RE FOR EXTRA PAGE FED 15 RE FOR PAPER JAM IN FEEDER 22 RE FOR SMALL SHEELT 17 RE FOR FEEDER SPEED IS TOO SLOW N 23 RE FOR FEED SENSOR 24 FOR TWO SHEET SENSOR 2049 RE FOR READ BOARD 39 RE FOR STACK SENSOR 5162 RE FOR ACCUMULATOR SENSQOR 5263 RE FOR ACCUMULATOR DUMP CLUTCH 5364 RE FOR FOLDER CIRCUIT BREAKER 6476 RE FOR TRANSFER CONVEYOR INFEED SENSOR 8068 ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 3 SMART FEEDER SERVICE MANUAL ISSUE 09 00 D 1c Systems Checks Switch the Smart Feeder 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 Smart Feeder 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 fe
16. 44 0020 19048 FOLDER ASSEMBLY page 5 46 0020 19048 FOLDER ASSEMBLY page 6 48 0020 17812 TRANSPORT CONVEYOR page 1 50 0020 17812 TRANSPORT CONVEYOR page 2 52 0020 18652 11 TRANSPORT CONVEYOR page 1 54 0020 18652 11 TRANSPORT CONVEYOR page 2 56 002E 19056 STRAIGHT CONVEYOR page 1 58 002E 19056 STRAIGHT CONVEYOR page 2 60 706 25697 400 LINE CODE READ OPTION 62 002K 08066 B amp H LINE CODE 64 002 20772 BAR CODE READER 3 OF 9 66 0020 20739 LASER SCANNER 68 002K 21390 FIRST PAGE HOLD 70 002K 23756 INK MARKER OPTION BELL amp HOWELL 74 389 26066 400 INK MARKER KIT 76 SMART FEEDER SERVICE MANUAL ISSUE 12 00 002K 21395 OPEN FEED SENSOR 78 002K 08432 INSERTER DEMAND SWITCH KIT 80 002k 07970 AC DC INSERTER CONTROL OPTION 82 186 035700600 3208 DOCUMENT LOADER page 1 84
17. AUX PUR i C MR A EEI pem pi 20 n C BI Woe sop HT 4 mm 7 E 5 WIE GRE RAE wm 815 iB L TEN ls E F am m Van ET C BIO i E BIT gt lt 2 9 m B BTS 7 8815 CER e lt 21 4 2 7 m T tl 28 3 OI s ov 8873 b 8872 b T Ea z ur Ba 2 ER T 4 5 namen E sus BID 581 mi nem bu 3 lt T En ABIT lt 1 2 1087 lt B Eo em x d MB E s 7 ABTS CE 5 MDBS LEZI sov UI P ABTA CEL a DAE SEEN T sup 3 f BI mE 3 6 d 8 m 7 ABTI 1 q 17 nium ABID n 3 2 E T i DOLI REN NEN 28 2494 zs xS en is ii BIK 24V RETURN PLANE RED ER PLANE 7802 RED 2AV POWER PLAN BK RETURN wR 4 tu 24V SWITCHED POWER PLANE 540 AUX GND 24 RET 3 WILL URS Si s 113 TNI X n DRAN UC DATE CHECKED DATE DATE THS ORANG YOR
18. MAN N i eu N ELECTRIC N l 002K 08133 775 LEFT HAND 6 STATION INSERTER KIT INDEX PART NUMBER DESCRIPTION 1 002B 08019 STATION 1 SENSOR CABLE 2 002B 08021 STATION ERROR T B CABLE 3 002B 08024 STATION 1 SENSOR ASSEMBLY 4 002B 08046 ELECTRIC BOX CABLE 5 002B 08051 ENCODER CABLE 6 002B 08052 CABLE B 6 STATION CONTROL 7 002B 08056 ERROR INDICATOR LAMP 8 002B 08120 CABLE A 6 STATION CONTROL 9 002 08132 INTERCONNECT CABLE 10 002B 08213 SENSOR AMPLIFIER 11 030 SMIDCF MODULE WHT SM IDC F 12 030 SMIDC5 MODULE WHT SM IDC5 13 030 SMODC5 MODULE RED SM ODC5 14 042 2281115 CONNECTOR BOARD 37 SUB D 15 526 26040 500 775 POSTAL METER INTERFACE CABLE SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 73 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 74 002K 23756 INK MARKER OPTION BELL amp HOWELL T 8 he T im Say DL 7
19. 2 A 3a FEEDER SECTION teer ere T ee 2 A 3b ACCUMULATOR SECTION 8 A 3c FOLDER SECTION 2 a a tit oiii cesses 10 A 3d POWER UNI Do 4 nti tete let ete EE 10 A3 e SENSORS EEF 12 EMERGENCY STOP INTERLOCKS eee 12 A 4 Machine Specification 15 SMART FEEDER SERVICE MANUAL ISSUE 09 00 INTRODUCTION 071 25287 400 SECTION A PAGE 1 SMART FEEDER SERVICE MANUAL 071 25287 400 1 REQUIRED MANUALS The following manuals are available for the 420 e NA N A A 2 INTRODUCTION TO THE MANUAL This manual is intended for service technicians and is organized to enhance preventive maintenance troubleshooting and repair of the Smart Feeder Installation of the Smart Feeder is also described A 3 INTRODUCTION TO THE MACHINE A 3a FEEDER SECTION The Smart Feeder s feeder is bottom fed top loading for continuous operation with a capacity of 1500 sheets 20 Ibs Creeper Conveyor 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 indicates that paper is low ISSUE 09 00 INTRODUCTION SECTION A PAGE 2 Hopper and 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 t
20. 34 D 4d Calibration of Line Code Recognition system 37 D 4e Computer Preset Line Read Page Set Up 38 D 4f Read Tolerance Selection 46 D 4g Recommended Line Code Configuration 47 D 4h Specifications of the Line Code System 48 D 5 3 of 9 LASER BAR CODE READ OPTION 53 D 5a Laser Safefy cie cim dee ear 53 D 5b Bar Code 54 D 5c Adjusting the Model 30 54 D 5d Setting the 420 to Read 3 of 9 Laser Bar Code 56 D 5e Adjusting the Paper Guides see 56 D 5f Laser Bar Code Read 57 D 6 ACCUMULATOR SECTIONN 61 D 6a Descfipti n i u DIOC Qe 61 D 6b Accumulator Clutch and Brake Adjustments 61 D 7 FOLDER FUNCTION ssosesssisssressssssoresssssssssvscsssoressssressesosssssress 65 D 7a DESCHPEON eoe DESEE 65 SMART FEEDER SERVICE MANUAL ISSUE 09 00 D 7b Fold Principl a eee 65 D 7c Components of the Fold 66 D 7d Features of the Fold 2222 69 D 7e Setup and Adjustments 70 D 7f Timing Procedures not applicable 73 D 7g Folder Infeed Roller Tension Adjustment 74 D 7h Removal and Replacement of Folde
21. WHT N U POWER K1 030 KUMP 1401824 N RETURN v BLU Bik i BU aK IR WT BL N ii 80 7 N 22 BANG GR SWITCHED 3 H T E 4 ken 003 ia ea 5 4 AWG J47 Y A NW E WG au 0 c Iu 3 U t ANG YEL GRN p4 4 ANG FEEDER TEMO XING FOR FOLDER
22. T d Le BY H Lb X i sin 002D 08156 KEYBOARD ASSEMBLY INDEX PART NUMBER DESCRIPTION 1 002B 08542 KEYBOARD CABLE 2 041 ATHO1982CLR CLEAR LENS 3 041 ATHO1982GRN GREEN LENS CAP 4 041 ATHO1982YEL YELLOW LENS 5 041 ATH25F1 SWITCH ELEMENT 6 041 OTH36F220 SWITCH 7 041 E22B1 CONTACT BLOCK 8 041 E22JLB2N8 E STOP SWITCH 9 600C 18709 KEYBOARD 10 600B 20846 KEY FOB SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 37 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 38 002D 19048 FOLDER ASSEMBLY PAGE 1 3 7 g al gt 4 N 002D 19048 FOLDER ASSEMBLY PAGE 1 INDEX PART NUMBER 1 041 35801 2 002C 17912 3 186 0340069800 4 002B 08539 5 600A 17923 6 600A 19002 7 600A 19003 8 600A 19083 9 600C 17931 10 600C 17851 11 600C 17954 12 600B 17773 13 018 12501500 14 186 034004422 15 039 39014030 039 39014036 DESCRIPTION MAGNETIC REED SWITCH FRONT COVER FOLD PLATE 3 MODULE TWO TERMINAL BLOCK HANDWHEEL MOD PULLEY BRACKET FOLDER PANEL
23. 1 b 2 General procedures 1 B 2a CLEANING THE MACHINE eerte 46 0 1 B2 b LUBRICATION en ae io 2 1 TEST EQUIPMENT AND TOOLS B 2a CLEANING THE MACHINE e Fluke Scope Meter The 420 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 e 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 B 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 B 2a1 Cleaning the Fold Rollers All accumulated paper dust should either be brushed or vacuumed from the 420 Clean all accumulated paper dust from DO NOT ATTEMPT TO CLEAN THE SMART FEEDER WHEN the electronic paper sensors THE MACHINE IS RUNNING ATTEMPTING TO DO SO COULD RESULT IN INJURY BE SURE THAT MACHINE B 2a2 Cleaning the Fold Rollers POWER IS OFF AT ALL TIMES WHEN CLEANING DO NOT USE ANY LIQUID ON THE FOLD ROLLERS The fold plates must b
24. Probable Cause Error only exists in Airtel style code Solution Perform read setup to ensure voltages are correct Check reader board with scope perform Reader Board RCP Check UARTs on CPU replace as necessary Replace software C 4s SYMPTOM Error in accumulator jam stall to ramps Paper is jamming at the accumulator ramps Probable Cause Paper left feed sensor and stack sensor did not see it in time Solution Check sensor adjust if necessary Check that paper is being properly fed Check speed and encoder timing Perform Feeder Speed input RCP C 4t SYMPTOM Error in accumulator Stall on ramp Paper is jamming at the accumulator ramps Probable Cause Solution Paper not being fed properly into the accumulator Check sensor adjust if necessary Check for paper jam into accumulator when stacking Check belts for slickness lack of friction Make sure paper path is clear into the accumulator Perform Accumulator Sensor input RCP C 4u SYMPTOM Error accumulator package did not dump Always occurs on power up with paper in the accumulator Paper is jamming at the accumulator ramps Probable Cause Solution Paper not able to clear the accumulator Perform Clutch RCP Perform Accumulator Sensor input RCP SYMPTOM Error accumulator package not removed Paper stalled in the accumulator Probable Cause Solution Package left in accumulator Remove pac
25. 3 002D 08156 KEYBOARD 4 002D 16435 SINGULATOR 5 002D 17505 CREEPER CONVEYOR 6 002D 19017 ACCUMULATOR 7 002E 19046 CABINET 8 002D 19047 FEEDER 9 002D 19048 FOLDER SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 3 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 4 001D 19045 SMART FEEDER FOLDER COVER ASSEMBLY 001D 19045 SMART FEEDER FOLDER COVER ASSEMBLY INDEX PART NUMBER DESCRIPTION 1 002D 18033 LEFT FEEDER COVER 2 002D 18034 RIGHT FEEDER COVER 3 113 20028003701 BELT TIMING 4 600B 18780 FILL COVER ACCUMULATOR 5 600B 20738 ROLLER COVER 6 600C 20707 BELT COVER 7 186 032029977 LEFT FOLDER COVER 8 186 032029976 RIGHT FOLDER COVER 9 600D 18779 ACCUMULATOR SIDE COVER SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 5 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 6 002E 19046 CABINET ASSEMBLY 3 Tu e a Tum 002E 19046 CABINET ASSEMBLY INDEX PART NUMBER DESCRIPTION 1 002C 07722 ADAPTER PLATE ASSEMBLY 2 002C 08495 001 POWER CABLE 3 002C 08495 002 POWE
26. Enable at 090 Enable at 080 6 2 100 Tick Encoder AC DC Dumb Inserter On at 200 for first Meter inline 240 if second meter inline Postal Meter 3 Off at 010 Insert Sta 07 Pt 1 On at 200 for first Meter inline 240 if second meter inline Postal Meter Weights Off at 010 Insert Sta 07 Pt 2 Meter 1 to 2 00004 Meter 2 to 3 00005 SMART FEEDER SERVICE MANUAL ISSUE 09 00 Weight Page and Envelope Page 00001 Envelope 00001 gt 00001 gt 00001 gt 00001 Weight Inserts 1 2 3 4 gt 00001 gt 00001 gt 00001 gt 00001 Weight Inserts 5 6 7 8 gt 00001 gt 00001 gt 00001 gt 00001 PROBLEM ANALYSIS SECTION C PAGE 15 SMART FEEDER SERVICE MANUAL Read T J Line Demand Feed Page sequence Group Sequence Ink Mark Postal Meter Divert Parity End of Subset Random Check Mark Blank Page Error Stop Number of Windows Window Setup Lines Per Inch Probe A or B Bit Weight Calibration Tolerance Code Field Format EOG Page Group Inserts Postal Meter Divert Subset Parity Random Check Mark Read Bar Job Setup Stop for Read Errors Normal Item Count Off Off ISSUE 09 00 Off Off 2 NO divert by mark and YES Meter 1 Weight None Off Off On 1 1 Begin 07 Length 16 6 A LSB First Off Low EOG 00 NOT EOG 00 Begin 5 Length 3 Min 1 Max 7 Begin 2 Length 3 Min 1 Max 4 Begin 10 Length 6 Max 6 At Line 0 At Line 0 By Count Size 0 At Li
27. GO TO TABLE OF CONTENTS 420 Service Manual ISSUE 12 00 071 25287 400 E 420 SERVICE MANUAL ISSUE 12 00 COVER 071 25287 400 E Lae NOTICE While every care has been taken in the preparation of this manual no liability will be accepted by GBR Systems Corporation arising out of any inaccuracies or omissions service documentation is supplied to 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 2000 by GBR Systems Corporation rights reserved Systems Corporation Copyright protection claimed
28. UNDO ENTER BEGIN HT HT HT LENGTH This display permits the operator to set the read window The operator sets the distance from the leading edge of the paper to the reading start and stop point The read window is the distance from the edge of the page to where the first line of code starts and the actual length of the code This measurement is either in sixths or eighths of an inch Example If there are eight lines of code to the inch and the code consisting of 10 lines starts one inch down the page The window would be set at BEGIN 008 LENGTH 10 SECTION D PAGE 42 12A7 LINES PER INCH CHOOSE LINE SPACING UNDO ENTER Lines per Inch 6 8 Use the cursor keys until the desired choice flashes Press ENTER The code marks can be at 1 6 or 1 8 inch spacing This is 6 lines or 8 lines per inch There can be as many as 25 mark locations in a bank EXAMPLE GRV EOG GS1 GS2 GS4 GS8 PS1 PS2 PS4 PAR NOTE Presence of a bar is binary 1 and the absence of bar is binary 0 The GRV mark must be located in the first position The 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 13 17 A or B Use the cursor keys lt gt until the desired choice flashes Press ENTER 14 17 BIT WEIGHTING CHOOSE LINE SPACING lt gt UNDO ENTER MSB LSB FIRST Move curs
29. 7 Li 16 O T U O A 7 0 1 10 1 E ux L NU 1 7 N Ber L E XI Y SU 16 002D 16435 SINGULATOR ASSEMBLY INDEX PART NUMBER N SMART FEEDER SERVICE MANUAL 002B 08212 002B 16325 002B 16326 002C 16500 014 SW15 181 03000301000 181 05000808125 600A 16435 003 600A 16435 004 600A 16435 005 600A 16435 006 600A 16914 600B 15915 044 177 25913 600 600B 16435 002 600B 16435 007 600B 16435 008 600B 16435 009 DESCRIPTION CREEPER CONVEYOR SWITCH INPUT BRACKET INFEED SWITCH BRACKET SUPPORT BAR ADJUSTING SCREW SPRING SPRING ADJUSTING SCREW ROLLER AXLE DETENT WAND PAPER DETENT AXLE HEX NUT STACK SWITCH ACTUATOR SINGULATOR ROLLER ROLLER GUARD ADJUSTING FORK ADJUSTING PLATE ADJUSTING KNOB ISSUE 09 00 PARTS SECTION I PAGE 23 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 24 002B 21905 OUTSIDE FEED BELTS 002B 21905 OUTSIDE FEED BELTS INDEX PART NUMBER 1 2 3 4 0028 21906 002A 21927 600A 22189 186 2823500088 600A 20965 600A 21908 600A 21909 DESCRIPTION HOUSING ASSEMBLY ROLLER ASSEMBLY IDLER
30. Error in read no response timeout 43 C 4f SYMPTOM Error in read code misread 43 C4g SYMPTOM Error in read group out of 44 C 4h SYMPTOM Error in read expected end of group 44 C 4i SYMPTOM Error in read blank 44 4 SYMPTOM Error in read short group a 45 C 4k SYMPTOM Error in read duplicate 45 C 41 SYMPTOM Error in read page out of 4 en 45 C 4m SYMPTOM Error in read invalid group 46 C 4n SYMPTOM Error in read expected page 46 C 4o SYMPTOM Error in read group out of range 46 SMART FEEDER SERVICE MANUAL ISSUE 09 00 C 4p C 4q C 4s C 4t C 4u C 4v C 4w C 4x C 4z C 4aa SYMPTOM Error in read page out of range SYMPTOM Error in read presets corrupt SYMPTOM Error in read yes no eog SYMPTOM Error in accumulator jam stall to ramps SYMPTOM Error in accumulator Stall on ramp SYMPTOM Error in accumulator package did not dump SYMPTOM Error in accumulator package not removed SYMPTOM Error in accumulator dump brake fail SYMPTOM Error in accumu
31. FOLDER ASSEMBLY PAGE 5 002D 19048 FOLDER ASSEMBLY PAGE 5 INDEX PART NUMBER 1 186 034003873 186 034003872 186 031029637 DESCRIPTION MOTOR 120 MOTOR 220V SET OF TWO MOTOR BRUSHES 2 186 034003900 110 120V PC BOARD 186 034003899 220 240V PC BOARD 3 186 032012435 PIN 4 186 032022136 PLATE 5 186 031029939 6 186 031037061 GROMMET 7 186 031027332 8 186 031118010 SET SCREW 9 186 032012436 EXTENSION 10 186 034003910 WIRING HARNESS 11 186 032027503 12 186 034003874 PHOTODETECTOR 13 186 031029287 CABLE TIE 14 186 031029290 GROUND SCREW M4 15 186 031029589 PLUG 16 186 031027284 SLEEVE 17 186 032001 001 SPACER RING 18 186 034003925 CABLE 19 186 032026398 BRACKET 20 186 034004372 CABLE 21 186 031029368 OVERLOAD PROT SWITCH 4A 186 031029610 OVERLOAD PROT SWITCH 2 5A SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 47 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 48 002D 19048 FOLDER ASSEMBLY PAGE 6 002D 19048 FOLDER ASSEMBLY PAGE 6 INDEX PART NUMBER DESCRIPTION 1 186 032011949 KNURLED NUT 2 186 032016568 SHAFT 3 186 032012520 KNURLED SCREW 4 186 034001911 LEVER ASSEMBLY 5 186 032012350 KNURLED SCREW 6 186 032026556 PAPER STOP 7 186 031003044 SPRING 8 186 031043025 SCALE INCH 9 186 031043024 SCALE METRIC 10 186 031027183 SPACER DISK 186 034002486 FOLD PLATE 1 ASSEMBLY S
32. RIGHT SIDE FRAME LEFT SIDE FRAME ELECTRICAL COVER DOWEL PIN PHOTO DETECTOR MALE CONNECTOR FEMALE CONNECTOR SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 39 PARTS SMART FEEDER SERVICE MANUAL ISSUE 12 00 SECTION I PAGE 40 002D 19048 FOLDER ASSEMBLY PAGE 2 3 002D 19048 FOLDER ASSEMBLY PAGE 2 INDEX PART NUMBER O GQ N 002A 23467 002B 08569 002C 17912 002B 08630 186 032017722 041 35701 050 83510590 113 200130037 600A 17792 186 031025148 600A 17794 600B 18194 600C 17954 014 M0451105 DESCRIPTION SHAFT INTERLOCK FRONT COVER ENCODER ROLLER MAGNET FILTER BELT TIMING PULLEY PULLEY PULLEY TOP COVER LEFT SIDE FRAME SHSS CUP POINT M4 X 5MM SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 41 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 42 002D 19048 FOLDER ASSEMBLY PAGE 3 002D 19048 FOLDER ASSEMBLY PAGE 3 INDEX PART NUMBER DESCRIPTION 1 002B 08630 ENCODER 2 186 031025148 PULLEY 3 113 200130037 BELT TIMING 4 600A 17794 PULLEY 5 186 034002514 GEAR ASSEMBLY 6 186 034004389 GEAR 7 186 034004539 BEARING ASSEMBLY INCLUDES 161 26250 00 BEARING 186 031021063 FLANGE 8 186 033500114 SPRING PLATE 186 034001917 BEARING ASSEMBLY 9 186 033000644 BRACKET 10 60
33. creeping of the flat green belts will cause the packages to become improperly gapped in the Transfer conveyor L OF DOCUMEN OF THIS SEAFT Transfer Conveyor Figure SMART FEEDER SERVICE MANUAL ISSUE 09 00 D 8f Position of the Transfer conveyor s outfeed guides It 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 D 8g 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 8h 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 REPAIR INFORMATION SECTION D PAGE 79 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 80 REPAIR CHECKOUT PROCEDURE FOR TRANSFER CONVEYOR INFEED SENSOR TRANSFER CONVEYOR INFEED SENSOR REFER TO SECTION F TRANSFER CONVEYOR SCHEMATIC Enter the TEST m
34. display 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 SMART FEEDER SERVICE MANUAL ISSUE 09 00 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 Smart Feeder D 4a1 Reader Board Values that can be Adjusted Through The Smart Feeder VIP Display e GAIN controls the amplitude of the 0 5 volt analog signal e 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 e LAMP controls the brightness of the reader probe e TRIP POINT 1 controls the voltage level at which an interrupt will be generated in a low to high voltage transition e TRIP POINT 2 controls the voltage level at which an interrupt will be generated in a high to low voltage transition REPAIR INFORMATION SECTION D PAGE 27 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 28 D 4b Setting Up the GBR Line Code Reader size and a very slight halo appears around it The width of the light beam image on the paper not D 4b1 Setting the Probe incl
35. ik D M T N LJ Ll gle 389 26066 400 INK MARKER KIT INDEX PART NUMBER DESCRIPTION 1 002B 07186 INK MARKER INTERFACE CABLE 2 002B 07188 MODULE 9 INTERFACE CABLE 3 002B 23702 SENSOR ASSEMBLY 4 002B 08540 CABLE 030 26071 000 MODULE 5 042 26080 500 INK MARKER DRIVE UNIT 6 526 26067 500 POWER CABLE SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 77 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 78 002K 21395 OPEN FEED SENSOR ASSEMBLY Z Sue IN ER L3 N CO dc N XII I ll J Y XA Y Y gt gt 5 Lr ZUR m 1 kr GA N A J J U 4 06 V J N Vd a a 002K 21395 OPEN FEED SENSOR KIT ASSEMBLY INDEX PART NUMBER DESCRIPTION 1 002B 07663 SENSOR ASSEMBLY 2 020 RA01020864 STANDOFF 10 32 X 4 3 600A 21394 REFLE
36. or 512k battery backed RAM 1 6k 32k 128k or 256k EPROM Two dedicated RS 232 serial ports Two configurable RS 232 RS 485 RS 422 serial ports Battery backed real time clock 24 programmable I O lines Four counter timers SBX interface 8 MHz 80186 microprocessor All CMOS for low power consumption Interrupt processing of serial ports timer counters SBX interface and STD Bus DMA transfers from STD Bus and SBX interface 16 and 20 bit STD Bus addressing PRINTED WIRING BOARDS SECTION E SMART FEEDER SERVICE MANUAL ISSUE 09 99 PRINTED WIRING BOARDS SECTION E PAGE 4 CPU 186 Board Figure E 2 E 3b Specifications Microprocessor 80186 16 bit external data bus Up to 16 MHz operation Unlimited external wait state duration Zero to three programmed wait states for or memory INTO SBX interrupt INT1 STD Bus interrupt INT2 Serial interrupt INT3 STD Bus INT1 acknowledge DMAO SBX DMA transfer DMA1 STD Bus DMA transfer On Board Static RAM SMART FEEDER SERVICE MANUAL Word or byte access JEDEC standard 28 or 32 pin devices Up to 512k bytes Minimum battery backed data retention of five years Minimum access time of 150 ns Address Range 0 to 3FFFFH with up to 256k bytes installed O to 7FFFFH with 512k byte RAM option On Board EPROM Word or byte access JEDEC standard 28 or 32 pin devices Up to 256k bytes Minimum access time of 254 ns at 8 MHz Address rang
37. 071 25287 400 SECTION A PAGE 5 SMART FEEDER SERVICE MANUAL 071 25287 400 Main 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 red 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 Feeder Section Figure A 3 ISSUE 09 00 INTRODUCTION SECTION A PAGE 6 Paper Level Detector This 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 The Paper Level Detector monitors the paper through a metal wand Singulator A two inch stationary orange 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 an F on the amplifier Double Detect Sensor Singulator Figure A 4 FEED CLUTCH gt FEEDER
38. 1 129 OFFSET 2 111 average 120 set both OFFSET 1 and 2 120 12 Change GAIN to 00 by going into SETUP gt READER SETUP gt CUSTOM SETUP gt 1 7 GAIN 00 and press ENTER 13 The reader setup is complete If the setup in section C2 d has been completed exit out of these READ screens and begin running paper through the machine NOTE When switching between probes or after the Smart Feeder has been switched off it may be necessary to repeat this setup procedure 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 A 0 d Test Points gO Ti Ground 3 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 000 ex 2 i go ol 5 E um 870 U C17 y4 P1 T6 OOOOOOOOOOOOOOOCOOU OOOOOOOOOOOOOOOOCO 1 0000000000 5800000000000 INTI GBR Line Code Board Figure ug pi SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 33 SMART FEEDER SERVICE MANUAL D 4c Troubleshooting the GBR Line Code Reader D 4c1 Line read 1 If you cannot get proper white level setup values do the following e Make sure that the probe lamp is bright If it is not bright follow the instructions i
39. 1 0 BOARD n n 8 1 1 8 8 9 9 10 RED BIK 2000 SYSTEM MOD CUTTER SENSOR CUTTER SENSOR 0028 m zum MOD 9 TO CLR N T Ti SIS TI 171 25 BLK 7 BLK 3 8 lt CLR OUTI2 07 RKER INTRFACI ON INTERC Ki I 3 5 5 PRES 24 l 21 23 13 M k B NK MARKER k SOLENOID LAMP k R L 53 5 K R BLU m ud 3 E 1 IM T 7 9 9 K _ 2 1 NE BRN T E Nc 4 4 5 ilt ii 7 lt 2 WE OL REPERI Dt ME 5 GRN YE 4 ES hs EA E L 1 lt mE 5 1 lt H 205 MA
40. 186 If bad does correction fix problem e Troubleshoot or replace the CPU 186 PWB SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 17 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 18 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 N 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 Smart Feeder 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 v Place one sheet of the current stock under the feed sensor 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 0 2 light when the sheet is under the sensor Y N Check the small fuse for opto relay 2 Check the optical relay e Check wiring from the Control Box to the Display e Check the wiring and connections for intermittent connections Is there 24 VDC between TB2 1 and TB2 2 Y N e Check the connection from the controller to the Feeder e Check the wiring e Check 24 VDC power
41. 186 035700600 3208 DOCUMENT LOADER page 2 86 186 035700600 3208 DOCUMENT LOADER page 3 88 186 035700600 3208 DOCUMENT LOADER page 4 90 186 035700600 3208 DOCUMENT LOADER page 5 92 186 035700600 3208 DOCUMENT LOADER page 6 94 750 26978 500 3208 FEEDER MECH INTERFACE 96 750 27576 500 3208 FEEDER ELECT INTERFACE page 1 99 750 27576 500 3208 FEEDER ELECT INTERFACE page 2 101 389 2641 3 401 420 RIGHT ANGLE INTERFACE 103 PARTS SECTION I PAGE 1 SMART FEEDER SERVICE MANUAL ISSUE 12 00 001D 19045 SMART FEEDER FOLDER TOP ASSEMBLY PARTS SECTION I PAGE 2 001D 19045 SMART FEEDER FOLDER TOP ASSEMBLY INDEX PART NUMBER DESCRIPTION 1 0020 08135 POWER UNIT A C BOX 2 002D 08137 CONTROL PANEL
42. CONVEYOR SENSOR EXIT SENSOR SPLIT CLAMP COLLAR EXIT GLIDE STRIP REAR ANCHOR BLOCK SIDE REINFORCMENT BLOCK CLAMP RING CLIP ROLLER WEIGHT STACKING WHEEL ASSEMBLY PRESSURE WHEEL ISSUE 12 00 PARTS SECTION I PAGE 59 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 60 002E 19056 STRAIGHT CONVEYOR PAGE 2 002E 19056 STRAIGHT CONVEYOR PAGE 2 INDEX PART NUMBER O SMART FEEDER SERVICE MANUAL 186 37123432 186 37CD30013 186 37CD30014 186 37123081 186 37CD3001 1 186 37123017 186 37CD30059 186 377112009 186 375050056 186 37CD30061 186 37123080 186 37CD30021 186 37CD40006A 186 375050040A 186 37123309 186 37CD30017A 186 37123036 186 37123102 186 37123139 186 379010352 186 37123275 186 37123305 186 37123314 186 37CD30120 186 37CD30020 186 37123664 186 37CD30130 186 37CD30030 186 37CD30140 186 37CD30040 DESCRIPTION C CLIP PIVOT STACKER WHEEL ROD BAIL WELDMENT C CLIP ROD STACKER WHEEL SCREW 10 32 X 25 CLAMP PLATE SPRING STACKER WHEEL PIVOT ASM PIN C CLIP 187 STACKER WHEEL BODY CLOSURE DRIVE ROLLER CONVEYOR TAPE RECEIVING TRAY ROLL PIN PULLEY TIMING BELT BEARING HOUSING ASSEMBLY SCREW 6 32 X 25 INDICATOR PLATE KNOB POTENTIOMETER ASSEMBLY POT ASM before s n 51284 POWER SWITCH TRANSFORMER 115V 60HZ TRANS 115V before s n 51284 TRANSFORMER 220V 50HZ TRANS 220V before s n 51284 ISSUE 12 00 27 28
43. Control Pot and Timer Disk are the connections to the Motor Control Board physically and electrically intact Y N Ensure physical connections are secure 3 Troubleshoot the following components replace as required e Motor Control Board e Speed Encoder blue on infeed roller shaft to Opto 3 Rack 0 e Folder Discharge Sensor to Opto 17 Rack 0 4 Unplug folder cord from power box Enter the TEST menu from the VIP display Select OUTPUT from the submenu and select Folder Motor output opto 1 1 Press the ENTER key and measure voltage at power box outlet J4 is it 120VAC Y Solid State Relay SSR3 be bad Perform SSR RCP 5 Reconnect folder cord and measure voltage at input end of motor control board terminals 16 and 17 is it 120VAC Y N Test the circuit for correct operating voltages refer to schematic in Figure D nn Locate the defective component and repair or replace as necessary Check wiring between power box and motor controller 6 Measure output voltage of motor control board terminals 13 and 14 110VAC Y N Controller is bad replace D 8 TRANSFER CONVEYOR D 8a Description The transfer conveyor is an articulated belt system which presents the nest folded document s to the Inserter gripper arm D 8b Timing Demand switch on off timing is critical The setup of this timing permits the Smart Feeder to achieve optimal handoff to the Inserter Move Closer To Increase Duration To PF30
44. D 2c Feeder Setup and Adjustments D 2c1 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 singulator 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 D 2c2 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 re
45. EOG was seen Inspect stock for packs out of sequence Check sequence count in read setup Up Down Off Check setup voltages to ensure dots are not being seen as lines verify by running stock with scope connected to read board Perform reader board RCP C 4k SYMPTOM Error in read duplicate page Same code read on two consecutive pages Probable Cause Solution The same page number was seen twice in one group Inspect stock for packs out of sequence Check sequence count in read setup Up Down Off Check setup voltages to ensure dots are not being seen as lines verify by running stock with scope connected to read bd Perform Reader Board RCP C 4 SYMPTOM Error in read page out of seq Page was not in correct order for package Probable Cause Solution The page sequence within a group did not properly increment or Inspect stock for packs out of sequence decrement Check sequence count in read setup Up Down Off Check setup voltage to ensure dots are not being seen as lines veriry by running stock with scope connect to read bd Perform Read Board RCP SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 45 SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 46 C 4m SYMPTOM Error in read invalid group Package contains pages improperly coded Probable Cause Solution Group sequence is not correct did not increment or decrement Inspect stock for pack
46. Four DUART input bits are supplied on each connector so that the node address can be hard wired into the mating connector for remote configuration To obtain the J7 node address D3 through D6 of the UBDUART input port must be read at address 811AH To obtain the J8 node address D3 through D6 of the U4DUART input port must be read at address 813AH To avoid conflicts SF6 must SMART FEEDER SERVICE MANUAL ISSUE 09 99 not be jumpered if the node address is to be configured remotely When configured for RS 422 J7is used for transmit and J8is used for receive When configured for RS 485 J7 and J8 are used as independent serial channels J7 uses the RXDA TXDA lines from the U8DUART for serial communication J8 uses the RXDB and TXDB lines from the UBDUART except when RS 422 is selected and then RXDA is used instead of RXDB This allows COM port protocols to remain consistent J7 and J8 RS 485 RS 422 Connector Interface Figure E 4 PRINTED WIRING BOARDS SECTION E PAGE 9 SMART FEEDER SERVICE MANUAL ISSUE 09 99 Counter Timer Interface J9 The CPU 186 has four counter timers These timer outputs and their corresponding counter inputs are brought to J9 The following illustration shows the pinout of This connector Counter timer sources come from the 80186 and the U4 and U8DUARTs 1 U8 COUNTER INPUT 02 Us TIMER OUTPUT 186 COUNTER 0 INPUT O 186 TIMER 0 OUTPUT GROUND 0
47. I PAGE 13 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 14 002E 19047 FEEDER ASSEMBLY PAGE 1 INDEX PART NUMBER 002 16437 002 22091 0028 08526 002B 08630 002B 16767 002B 21905 002B 22221 002B 19633 002D 08522 002D 16435 002D 17505 002D 18099 095 25212 600 112 200DBA30637 112 200DBA32637 112 200DOA30637 113 S290XL100 547 25937 500 547 25938 500 600A 16349 020 600A 18773 DESCRIPTION PULLEY PULLEY MOTOR ENCODER PULLEY OUTSIDE FEED BELTS PULLEY TRIPLE BEARING BLOCK FEEDER ELECTRICAL ASSEMBLY SINGULATOR CREEPER CONVEYOR SINGULATOR COVER SHAFT PULLEY TIMING 30T PULLEY TIMING 32T PULLEY TIMING 30T BELT TIMING LEFT CHASSIS ASSEMBLY RIGHT CHASSIS ASSEMBLY DRIVE PULLEY SCAB PLATE 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 600B 15839 014 600B 15839 017 600B 15839 028 600B 15839 060 600B 15839 125 600B 20151 600B 16122 033 600B 16404 005 600B 16430 600B 17045 600B 17312 600B 17540 600B 17541 600B 17848 600B 18045 600D 17316 600D 19007 600D 19008 600D 22275 025 25947 500 002B 08462 HANGER GUIDE RAIL TENSIONER SHAFT TIE BAR RAIL GUIDE DRIVE PULLEY FRONT TIE PLATE SINGULATOR DRIVE SHAFT HOPPER FEED SHAFT ROLLER BEARING HUB DRIVE ROLLER UPPER SHAFT FEEDER MOUNT BAR UPPER PULLOUT ROLLER LOWER PULLOUT ROLLER UPPER PULLOUT SHAFT FEEDER BELT FEEDER DOCKING PORT PAPER GU
48. JAM EXITING CONVEYOR A document has jammed under or into the conveyor exit sensor transfer conveyor sensor The into transfer conveyor or exit sensor is out of adjustment or has failed or been move Paper dust on sensors PRESETS CORRUPT Battery drained or failed presets don t match Power down machine to restart NOT ENOUGH NV RAM comparator Battery failed or battery jumper missing Bad CPU 186 board STATE DIDN T CHANGE Paper feed attempted but not completed 1 State of Trans IN or Trans OUT sensor incorrect ON should be OFF or vice versa INT LINE OVERHANG Paper went past the exit sensor 1 Outfeed fingers misadjusted NO PACK IN FIRST STA Expected package at transfer conveyor infeed 1 Infeed sensor is misadjusted sensor 2 Paper jam in folder NO PACK IN LAST STA Expected package at transfer conveyor exit 1 Paper jam in transfer conveyor registers indicate need for package FIRST STA NOT EMPTY Did not expect a package at transfer conveyor 11 The package has jammed or skewed in the infeed sensor transfer conveyor infeed 2 The in transfer conveyor exit sensor has failed 3 Powered down and memory cleared but package still there LAST STA NOT EMPTY A package did not exit transfer conveyor after 1 The package has jammed the transfer indexing conveyor exit 2 The transfer conveyor station exit sensor has failed 3 Powered down and memory cleared but package still there JAM IN CONVEYOR C Into transfer Conveyor jam
49. MECH ASSEMBLY 389 26413 401 420 RIGHT ANGLE INTERFACE T F 2105 LEN FN 13 bord FN D ki T F i N VEY 5 RIGHT SIDE VIEW SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 103 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 104 389 26413 401 420 RIGHT ANGLE INTERFACE INDEX PART NUMBER DESCRIPTION 1 024 16471621 END STOP 2 025 PN226F SPADE LUG 6 3 026 TFT20018 TEFLON TUBING 4 030 26318 500 BOWE STOP RELAY ASSEMBLY 5 030 2CAD14D10 RELAY 6 031 SR3PO5 RELAY SOCKET 7 041 ATH25F1 SWITCH ELEMENT 8 041 E22B2 CONTACT BLOCK NO 9 067 V33ZA5 VARISTOR 10 194 25606 602 DIN RAIL 11 526 26312 500 CAB
50. 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 12 00 PARTS SECTION I PAGE 95 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 96 750 26978 500 3208 FEEDER MECH INTERFACE SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 97 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 98 750 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 310313
51. POSITIVE POTENTIA CONNECT POINT WITH GREATEST NEGATIVE POTENTIA o CONNECTION BETWEEN STATION 5 CONTROL SWITCH AND STATION 5 SOLENOID BREAK CONNECTION CONNECT TO SWITCH CONNECT TO POINT WITH GREATEST POSITIVE POTENTIAL PROBABLY SWITCH WHT OR OTHER SIDE 0 ON BROKEN ABOVE 3 EMEST NEGATIVE POTE p CONNECT TO SOLENOID CONNECT TO POINT WITH GREATEST NEGATIVE POTENTIAL PROBABLY SOLENOID At i I WHT CR gt CONNECT THESE TWO WIRES IN SERIES WITH STATION 5 ERROR DETECT SWITCH CONNECT TO POINT WITH GREATEST POSITIVE POTENTIA no CONNECT TO POINT WITH GREATEST NEGATIVE POTENTIA m CONNECTION BETWEEN STATION 6 CONTROL SWITCH AND STATION 6 SOLENOID BREAK CONNECTION CONNECT TO SWITCH CONNECT TO POINT WITH GREATEST POSITIVE POTENTIAL PROBABLY SWITCH WH OTHER SIDE OF CO ON BRO OVE ji p CONNECT TO SOLENOID CONNECT TO POINT WITH GREATEST NEGATIVE POTENTIAL PROBABLY SOLENOID WHT BLK BRN gt CONNECT THESE TWO WIRES IN SERIES STATION 6 ERROR DETECT SWITCH CONNECT TO POINT WITH GREATEST POSITIVE POTENTIA CONNECT TO POINT WITH GREATEST NEGATIVE POTENTIAL CONNECT TO A POINT IN THE CIRCUIT THAT WILL GENERATE 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 NETT CONNECT TO SOLENOID CONNECT TO POINT WITH CREATEST NEGATIVE POTENTI
52. PROCEDURE FOR A MULATOR DUMP CLUTCH ACCUMULATOR DUMP CLUTCH REFER TO SECTION 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 the 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 Replace the CPU 186 PWB Check the accumulator sensor v D 7 FOLDER FUNCTION D 7a Description Fed by the Accumulator Section the folder is capable of placing 1 to 5 folds in a C Z V or 7 double V configuration See Fold Capability 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 on the particular configuration docu
53. Page Sequence marks must be present when using PAGE SEQUENCING SMART FEEDER SERVICE MANUAL ISSUE 09 00 3 17 GROUP SEQUENCE GROUP SEQUENCE UNDO ENTER UP DOWN MATCHING OFF entire set UP DOWN MATCHING OFF same sets OK UP DOWN MATCHING OFF sets must change UP DOWN MATCHING OFF UP DOWN MATCHING OFF entire set Use the cursor keys until the desired choice flashes Press ENTER 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 OFF If there is no group sequence enter OFF 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 4 17 INK MARKING INK MARKING lt gt UNDO ENTER ON OFF REPAIR INFORMATION SECTION D PAGE 39 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 40 5 17 POSTAL METER POSTAL METER UNDO ENTER ON OFF 6 17 PARITY PARITY lt gt UNDO ENTER EVEN ODD NONE Use the cursor keys until the desired choice flashes Press ENTER Some code formats require an odd or even number of lines for parity The programmer determines the use of PARITY Pari
54. SECTION D PAGE 9 SMART FEEDER SERVICE MANUAL 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 a Carefully position the singulator using the small amount of play available to raise the side of the singulator that has the most tension b Tighten the 10 32 x 5 8 socket head cap screws loosened in step 5 c Retest the tension of the two strips of paper by returning to step 3 ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 10 Rotating Singulating Roller The Singulating Roller is the place where the highest frictional forces are created These frictional force
55. SPEED ENCODER 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 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 LOCKING SET SCREW rm SMART FEEDER SERVICE MANUAL ISSUE 09 00 INTRODUCTION 071 25287 400 SECTION A PAGE 7 SMART FEEDER SERVICE MANUAL ISSUE 09 00 INTRODUCTION 071 25287 400 SECTION A PAGE 8 Feed Clutch Electrical clutch which engages the feed belt at a signal from the controller Optical Mark Reader or Read Sensor Reflective beam sensor 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 A 3b ACCUMULATOR SECTION The accumulator is fed paper from the singulator assembling groups of one to seven documents When the document package is complete it is fed to the folder Stacking Ramps Stacking Ramps are 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 Dump Brake This
56. Station 7 Select Inverted Signal 6 Station 8 Select Inverted Signal 7 Inserter E Stop Inverted Signal 8 Station 1 Error Inverted Signal Postal Meter Weights e Meter 1 to 2 Weight Value 00000 to 60000 e Meter 2 to 3 Weight Value 00000 to 60000 Weight Page and Envelope e Enter Page Weight Value 00000 to 60000 e Enter Envelope Weight Value 00000 to 60000 Weight Inserts 1234 e Enter Insert gt 1 Weight Value 00000 to 60000 e Enter Insert gt 2 Weight Value 00000 to 60000 e Enter Insert gt 3 Weight Value 00000 to 60000 e Enter Insert gt 4 Weight Value 00000 to 60000 Weight Inserts 5 6 7 8 e Enter Insert gt 5 Weight Value 00000 to 60000 SMART FEEDER SERVICE MANUAL ISSUE 09 00 Enter Insert 26 Weight Value 00000 to 60000 e 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 e Meter 2 operates e Package Weight greater than Meter 2 to 3 Weight Value Meter 3 operates PROBLEM ANALYSIS SECTION C PAGE 17 SMART FEEDER SERVICE MANUAL C 3 SOFTWARE ERROR CODES C 3a General Solutions to 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
57. UNEXPECTED SHEET Software routines could not compete a task 1 STATE DIDN T CHANGE PROBLEM ANALYSIS SECTION C PAGE 24 Accumulator jam The stack sensor is out of adjustment Accumulator jam The stack sensor is out of adjustment The dump nip rollers are out of adjustment The accumulator presence sensor is out of adjustment The dump clutch has failed Paper dust The accumulator presence sensor is out of adjustment The accumulator presence sensor has failed The dump nip rollers are out of adjustment The accumulator presence sensor is out of adjustment The accumulator presence sensor is out of adjustment The dump brake has failed KBIC settings need adjustment Belts slipping Encoder or tachometer failure Paper dust The accumulator presence sensor is out of adjustment Document in accumulator was not expected by 1 Adjust feed stack sensors the software Restart machine 2 Check 5VDC and 24VDC power supplies SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 25 SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 26 NO SHEET WAS FED Attempt to feed a document failed The singulator feeder belts are improperly adjusted The hopper is out of paper The hopper is out of SHEET WAS TOO SHORT A sheet was measured shorter than expected A jam occurred at the feed sensor The user selectable length preset by MODE key is too long The feed sensor and or accumulat
58. W MODULE SPEED W MODULE RED R BELT TIMING 40DP PULLEY ISSUE 12 00 PARTS SECTION I PAGE 83 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 84 186 035700600 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 12 00 PARTS SECTION I PAGE 85 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 86 186 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 12 00 PARTS SECTION I PAGE 87 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 88 186 035700600 3208 DOCUMENT LOADER PAGE 3 186 035700600 3208 DOCUMENT LOADER PAGE 3 INDEX PART NUMBER DESCRIPTION 1 1 029 244 SWITCH 2 1
59. 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 e Check the connection from the controller to the Feeder e 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 N Replace the CPU Correct the wiring SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 15 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 16 REPAIR CHECKOUT PROCEDURE FOR FEEDER MOTOR When the Smart Feeder is powered creeper power is supplied to the Feeder via AC outlet J2 of the power supply box The AC 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 e sure that SW15 is closed and that no emergency switch is open e Check fuses F1 and F2 e Check wiring between the LF4 and creeper motor The power is applied to the AC outlet th
60. asking which test to perform Press the lt or gt key to scroll through the available choices until INPUT is highlighted Press ENTER to select The display will then indicate the status of the input 00 00 OFF NAME OFF ON or UNAVAILABLE Physically change the input for instance cover a sensor to diagnose that the input is operating Its state should change as indicated on the display Also the LED on the associated optical relay will be OFF or ON depending on the state of the input Rack Opto indicates the location of the associated optical relay Press to see information for each input as described below Located on Used for Part No PROBLEM ANALYSIS SECTION C PAGE 3 SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 4 oe 2 ag 8D 8 ru 15 9 Led T i I gt 5 Bl O mt J m O L o a 535 VOLT OPTO MODULES LO qe J ci D
61. code etc The sensors index the number of sheets as they pass incrementing a count on the CPU 186 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 SMART FEEDER 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 ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 18 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 Before powering up the SMART FEEDER the operator must remove any packages in the accumulator to be sure there will be no initial error conditions C 3b Solutions to Less Common Errors A 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
62. e lower cover over the 2 buckle plate e folder and transfer conveyor meeting point interrupts power when the transfer conveyor is removed e clear lexan cover of the transfer conveyor TJ Line Code Reader placement could be on top or bottom left or riaht Stack Sensor Accumulator Sensor Feed Sensor Matant Canane Exit Transfer Conveyor Feeder Encoder Paper Demand Switrh Senenr Sensors Figure A 6 SMART FEEDER SERVICE MANUAL ISSUE 09 00 INTRODUCTION 071 25287 400 SECTION A PAGE 13 A 4 MACHINE SPECIFICATION Listed below are specifications for the Smart Feeder Throughput Speed Max 24 600 documents per hour Paper Weights 20 75 GSM Inquire for heavier weights Paper Size 7 x 7 178 mm x 178 mm to 11 x 14 305 mm x 356 mm Loading Capacity 2 000 sheets of 20 bond Fold Types C Z V amp DOUBLE V Porosity 20 Gurley seconds Stiffness 20 Lb Stock 170 225 Gurley Stiffness Units 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 Grou
63. eu SSRA 4 RED BIK 3 3 2 lt lt BLU PAK 4 E eu ib a 5 5 lt en 6 gt en 2 RN _ y me 59 3 om ORN INTER en 4 ie 8 10 H gt 2 n W 5 gt MT 5 W FEED CLUICH 0 WPI 0028 08799 NOTES ALL SWITCHES SHOWN IN NORMAL POSITION 2 DOT INDIC BLOCK UNLESS TE NS WE 4 MODULE 7 JUMPER IN PLAGE FOR 0 elephone SST VIVE AL ARIS mE SHEET 2 DOSO mnaq PACTOS A 1 58 MATERIA RR OCC we DRAWN uc DATE 2 10 FINISH WE ASS TLE APPROVED Vs i 14 TONT SAE SCALE m
64. light Y N e Check the optical relay e Check optical relay fuse Enter Diagnostics Select TEST Speed Option Does the Feeder speed indicate 50 IPS Y N e Adjust the speed of the Feeder e Replace the speed sensor e Replace the KBIC Controller SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 23 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 24 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 Is the green LED ON e Adjust the sensor N Check a different input to ensure the audible signal on the display is working e 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 sensor amplifier is set for Dark ON correct if necessary e Check the pico fuse of the opto module Replace the input opto module if necessary Is the problem corrected Y N Replace the CPU 186 PWB Set up and run the machine Run the machine Check the singulator setup Is the feeder providing pap
65. line1 4 above your gate mark say your gate mark is at line 15 on the page and you are set to 1 8 line spacing 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 1 s appear but they seem to have shifted on the page there are not the proper number of spaces between the 1 s 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 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 The 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 3 If the probe lamp is not bright do the following SMART FEEDER SERVICE MANUAL Look at the probe in questio
66. mode is set to ON Setup 15 DUMP TO FEED DELAY should be set to 05 and Setup 16 DUMP DELAY TIMER SETUP should be set to 40 These settings may need to be adjusted if other than 11 documents are being fed 12 8 Inserter ONLINE allows the Smart Feeder to control the operation of the inserter OFFLINE returns control to the inserter allowing the operator to run the inserter as a standalone unit This feature only works if the optional AC DC opto logic kit is installed This feature replaces the Dummy Plug that needed to be installed for inserter off line operation 13 18 First Page Hold Delay is normally set at 05 If the First Page Hold Option is installed on the Smart Feeder this time can be adjusted to leave a document on the accumulator ramps for a longer period of time if necessary 14 18 Config ID is normally set to XFER CONVEYOR W INSERTER XFER CONVEYOR W INSERTER P is selected when an insert from the Smart Feeder may not be desired and always selected when feeding a Pinnacle inserter Refer to Section for more information on SMART FEEDER SERVICE MANUAL ISSUE 09 00 15 18 Dump to Feed Delay Timer Setup is normally set to 10 30 if First Page Hold is being used A DUMP TO FEED DELAY of less than 10 may cause the first page of the set to be passed to the accumulator while the dump clutch is still engaged causing a DUMP BRAKE FAILURE error The amount of time allotted to the reader is dictated by
67. 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 186 PWB Run the machine Check the paper transport Are belts carrying paper v REPAIR CHECKOUT PROCEDURE FOR A MULATOR SENSOR ACCUMULATOR SENSOR REFER TO SECTION F ACCUMULATOR Enter the TEST menu from the VIP 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 186 PWB SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 63 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 64 REPAIR CHECKOUT
68. plates or paper stops to complete the desired folded package D 7c2 DELIVERY ROLLERS The delivery rollers move the package to the output module Position 1 Position Position 2 Delivery Rollers Position 4 Fold Rollers REPAIR INFORMATION SECTION D PAGE 66 Fold Roller Diagram Figure D7 c3 FOLD PLATES DEFLECTOR PLATES FOLD PLATE This fold plate is always in Position 1 See chart on fold plate and deflector plate positions FOLD PLATE II Use this plate in position 2 and 4 either as a fold plate FP or a deflector plate DP See chart on fold plate and deflector plate positions FOLD PLATEIII DP III This fold plate is always in position 3 Place it at the second fold Reverse the plate to use H as deflector plate See chart on fold plate and deflector plate positions DO NOT ATTEMPT TO ADJUST THE FOLDER WHILE THE POWER IS ON HANDS CAN BE SERIOUSLY INJURED SHUT OFF MAIN POWER BEFORE OPENING THE SAFETY COVERS SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 67 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 68 Folding Pockets Fold Style 12 C 80 x s Address x leading and x gt 2 3 1 3 LT X Fraction of each sheet in each pocket le 1 2 3 2 C Half Sen Facing Edge gt 213 1 3 X up 2 3 7 ass z pe 1 2 X Facin
69. prohibits the rollers from releasing paper from the accumulator Dump Clutch This activates the stacking rollers releasing the accumulated pages Accumulator Sensor The Accumulator Sensor indicates presence or absence of a package in the accumulator It also monitors package discharge when the dump clutch has been engaged Stack Sensor Indicates the document has cleared the stacking ramps Accumulator Section Figure A 4 SMART FEEDER SERVICE MANUAL ISSUE 09 00 INTRODUCTION 071 25287 400 SECTION A PAGE 9 SMART FEEDER SERVICE MANUAL 071 25287 400 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 110VAC motor which drives all folder shafts and rollers Folder Speed Encoder An encoder located on the infeed roller shaft which provides a folder speed signal 3 BUCKLE PLATE ISSUE 09 00 INTRODUCTION SECTION A PAGE 10 A 3d POWER UNIT The Power Unit is located inside the cabinet and consists of the following components Folder Section Figure A 5a
70. provide optimum document processing security 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 End of Package Purpose Controls the size of dynamic packages by indicating the end of a package Usage A solid bar is placed in this location on the page with the largest page ID number All other pages within a package should have no mark in this area Page ID number Optional 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 SMART FEEDER SERVICE MANUAL ISSUE 09 00 Package ID number Optional 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 Usage It is interpreted as a binary number This number must be constant for all the 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 Error checking Parity bit Optional Purpose Adds parity error checking to the code Usage This location is used to maintain an even n
71. right side bracket will drop 5 Remove rear plate Remove two phillips head screws Inserter Hopper Figure G 1 holding T plate in place remove T plate G 3 REMOVE SINGULATOR FINGER NOTE View of Fig G 2 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 G 2 SMART FEEDER SERVICE MANUAL ISSUE 09 00 INSTALLATION SECTION G PAGE 3 SMART FEEDER SERVICE MANUAL ISSUE 09 00 INSTALLATION SECTION PAGE 4 G 4 420 INTERFACE COUPLING u The machine is designed to permit the operator to connect the 420 directly to the inserting device The output is conveyed to NENNEN 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 th
72. the 420 for PAGE 00000 and the weight of an envelope for ENVELOPE 00000 ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 14 17 Weight Inserts 1234 should be set to the weight of an insert for each insert station 1 4 18 Weight Inserts 5678 should be set to the weight of an insert for each insert station 5 8 C 2g POSTAL METERING SETUP PRESETS The following are Typical Presets for the Smart Feeder configured for 6 Station AC DC Open Feed Inserter Control with two postal meters Meter 2 and Meter 3 Meter 1 and Meter 2 This may vary from your actual application Test Setup Double Detect ON Presets Reset NA Lower Left Display OMR Lower Right Display OMR No Use Timeout OFF Pulse Feed ON Type of Transfer OPEN FEED Beep Bell ON Input Conveyor 2000 Sheet Conveyor High Count Stop 07 Performance Off Inserter Online Offline Online First Page Hold delay 30 Config ID Xfer Conveyor W Inserter Dump to Feed Delay Setup 05 Dump Delay Timer Setup 25 Test Inserter Insert Vacuum Enable Envelope Hopper Vacuum Envelope Flap Detect Ink Marking Postal Meter Divert On at 100 On at 230 Insert Sta 2 On at 010 Off at 350 Insert Sta 1 On at 010 Off at 010 Insert Sta 00 On at 200 First Meter inline when Meters 1 and 2 tested Logical Shift Bad Package Stop Number of Insert Stations Number of Empty Stations Encoder Type Opto Logic Type Postal Meter 2 Off at 010 Insert Sta 07
73. the power to the Smart Feeder and now it should be OK to run NOTE VALUES FOR FUTURE REFERENCE To find the values go to SETUP READER SETUP gt CUSTOM SETUP and write down the values listed there GAIN OFFSET 1 OFFSET 2 LAMP REPAIR INFORMATION SECTION D PAGE 36 0 44 Calibration of Line Code Recognition system 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 both 1 8 code spacing and 1 6 code spacing There is a different calibration 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 and 1 8 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 0 441 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 e
74. to J91 of Opto Board 1 J1 to CN1 of Reader Board J2 to J2 of CPU 186 Board I O Board Module 1 Feeder Module 2 Folder Module 3 Power Unit Module 4 Transport Conveyor Module 5 Keyboard Module 6 Accumulator Module 7 Inserter Module 48 470 Feeder option CP 186 LED 1 Heartbeat green LED 2 red not used LED 3 green not used LED 4 Reset red E 3 PRINTED WIRING BOARDS PWB E 3a Introduction The CPU 186 is a multifunction single board computer designed for use on the STD Bus The board uses the 80186 microprocessor for high performance 16 bit processing of up to 512k bytes of on board data Off board I O and memory accesses are eight bits The board features four asynchronous serial ports with programmable data rates from 50 baud to 38 400 baud Two ports are dedicated RS 232 channels and two can be configured in one of the following combinations Two RS 232 channels Two RS 485 channels One RS 485 channel and one RS 232 channel One RS 422 channel and one RS 232 channel Other functions include 24 parallel I O lines 4 counter timers for digital acquisition and control a battery backed real time clock battery backed RAM and an optional math CO processor The standard board uses CMOS parts for low power operation and runs at 8 MHz 10 MHz and 12 MHz options are available SMART FEEDER SERVICE MANUAL ISSUE 09 99 Standard Features 64k 128k 256k
75. 0 Folder Magnets Slide To Change gt Duration The Demand switch should turn on contacts closed Magnetic when the gripper arm is approximately perpendicular to Reed Switch ee Switch Enlarged the deck of the Inserter The Demand switch should then 89 Proper Timing at Left turn off contacts open as the gripper arm completes it s ie backwards motion and starts moving toward the Transfer Length convevor D Point at which gripper arm takes pack 2 Demand switch turns ON 8 Demand switch turns OFF Transfer Conveyor Demand Switch Figure SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 77 SMART FEEDER SERVICE MANUAL D 8c Exit sensor Test on the Transfer conveyor The Exit sensor on a 420 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 Smart Feeder 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 ca
76. 0 OFF at 010 STA 07 PT 01 13 NOT USED 14 POSTAL METER 3 ON at 280 OFF 010 STA 07 02 15 POSTAL METER WEIGHTS METER 1 to 2 00000 METER 2 to 3 00000 16 WEIGHT PAGE AND ENVELOPE PAGE 00000 ENVELOPE 00000 17 WEIGHT INSERTS 1234 gt 00000 gt 00000 gt 00000 gt 00000 18 WEIGHT INSERTS 5678 gt 00000 gt 00000 gt 00000 gt 00000 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 1 Insert Vacuum is normally enabled at 100 This is the position of the encoder in degrees at which vacuum is applied to the insert station 2 Envelope Hopper Vacuum is normally enabled at 230 This is the position of the encoder in degrees at which vacuum is applied to the envelope hopper Insert Sta is normally set at 2 3 Envelope Flap Detect is normally set On at 010 Off at 350 and Insert Sta 1 this is the location of the flap detect 4 Ink Marking 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 NOTE ON POSTAL METER WEIGHING The 420 can accommodate up to three postal meters Based on the values entered in Postal Meter Weights Weight Page and Envelope Weight Insert
77. 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 12 00 PARTS SECTION I PAGE 89 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 90 186 035700600 3208 DOCUMENT LOADER PAGE 4 2 i E ES LES 1 E ee i EF NN 4 5 E 6 ES me 186 035700600 3208 DOCUMENT LOADER PAGE 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 12 00 PARTS SECTION I PAGE 91 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 92 186 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 12 00 PARTS SECTION I PAGE 93 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 94 186 035700600 3208 DOCUMENT LOADER PAGE 6 186 035700600 3208 DOCUMENT LOADER PAGE 6 INDEX PART
78. 08 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 RIGHT GUIDE RAIL 19 600D 20963 SINGULATOR COVER 750 27576 500 3208 FEEDER ELECT INTERFACE PAGE 1 s i ii X i Lum pim Ili mum Bu 4 Do SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 99 SMART FE
79. 0A 18845 SHAFT 11 186 033500174 GEAR WITH BUSHING 12 186 031119002 SET SCREW 13 186 034004383 BEARING 14 186 0831 176001 SHEET METAL SCREW 15 186 031146003 SET SCREW 16 186 031118005 SET SCREW 17 186 031176001 SHEET METAL SCREW 18 186 031025061 PULLEY 19 186 034006465 GEAR 20 186 031033015 V BELT 21 600A 17792 PULLEY 22 186 034004415 GEAR 23 186 034005622 IDLER GEAR SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 43 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 44 002D 19048 FOLDER ASSEMBLY PAGE 4 002D 19048 FOLDER ASSEMBLY PAGE 4 INDEX PART NUMBER DESCRIPTION 1 186 034001918 ROLLER 2 2 186 034001910 ROLLER 5 3 186 032017722 ROLLER 1 4 186 031135001 KEY 5 002B 08569 INTERLOCK MAGNET 6 186 034004401 ENCODER DISC 7 186 033000644 BRACKET 8 186 033500114 SPRING PLATE 9 186 033500495 BEARING 10 600A 19003 PULLEY 11 014 082511030 SET SCREW 12 600A 19002 HANDWHEEL 13 186 031107005 WASHER 14 186 031108001 LOCK WASHER 15 186 0831 176001 SHEET METAL SCREW 16 186 031052021 BEARING ASSEMBLY INCLUDES 161 26250 000 BEARING 186 031021063 FLANGE 17 186 033500515 TRANSPORT ROLLER 18 186 032016443 SHAFT 19 186 033500515 TRANSPORT ROLLER 20 186 033500515 TRANSPORT ROLLER 21 186 034001919 ROLLER 3 4 and 6 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 45 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 46 002D 19048
80. 18704 SPAN BLOCK 24 600A 18836 GUIDE BLOCK 25 600A 18986 SUPPORT BRACKET 26 600B 15839 028 TIE BAR 27 600B 17541 PULLOUT ROLLER 28 600B 17669 PAPER RAIL 29 600B 17714 INPUT SHAFT 30 600B 18707 STACK BLOCK 31 600B 18983 COVER SLIDE 32 600B 18995 BELT 33 600D 18715 PAW GUARD 34 600D 18771 CHASSIS SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 31 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 32 002D 19017 ACCUMULATOR PAGE 2 600A 19704 Y 002D 19017 ACCUMULATOR PAGE 2 INDEX PART NUMBER DESCRIPTION 1 002B 08157 BRAKE 2 002B 08445 INTERLOCK 3 002B 16342 DRIVE ROLLER 4 002B 19014 CLUTCH SHAFT ASSEMBLY 5 002D 08528 DISPLAY PANEL 6 002D 19016 TOP COVER 7 002D 19442 SENSOR PLATE ASSEMBLY 002B 08570 SENSOR MODULE ONLY 8 013 M10041 HEX NUT M10 9 014 04041104 BHSCS 4 40 X 25 10 014 10421110 SHCS 10 24 X 625 11 014 10021130 SHCS M10 X 30MM 12 592 25338 600 GUIDE 13 600A 18836 GUIDE BLOCK 14 600B 15839 028 TIE BAR 15 600B 17669 PAPER RAIL 16 600B 18707 STACK BLOCK 17 600B 18983 COVER SLIDE 18 600D 18715 PAW GUARD
81. 19 600D 18771 CHASSIS SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 33 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 34 002D 19017 ACCUMULATOR PAGE 3 002D 19017 ACCUMULATOR PAGE 3 INDEX PART NUMBER 002D 08156 002D 19016 002D 19442 013 M10041 014 M10021130 112 200D0A24637 112 200D0A25637 113 200170037 113 200240037 600D 18771 Q O OQ Q N DESCRIPTION KEYBOARD ASSEMBLY TOP COVER SENSOR PLATE HEX NUT M10 SHCS M10 X 30MM PULLEY TIMING 24T PULLEY TIMING 25T BELT TIMING BELT TIMING CHASSIS SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 35 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 36 002D 08156 KEYBOARD ASSEMBLY bs POWER CYCLE DUMP EMERGENCY ON STOP N N El 2 TN 9 52 NA N N N M N 9 Al l e a N U J 5 pud DITE
82. 2 00 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 600 17700 600 17708 600 17709 6000 17724 6008 17725 600 17728 6008 17729 600 17732 600 17733 6004 17734 6004 17735 6008 17737 6004 17785 600 17829 6008 17882 6000 18035 6008 18108 6008 18109 600 18140 6008 18540 6008 18567 600 18568 6008 19011 600 19061 6008 19304 6008 19305 DRIVE PULLEY RIGHT RAIL LEFT RAIL LEFT SIDE PLATE CONVEYOR SHIELD CONVEYOR SHIELD SUPPORT BAR COVER COLLAR GEAR RIGHT PIVOT STOP INFEED GUIDE LEFT PIVOT STOP SHAFT INFEED GUIDE RIGHT SIDE PLATE RIGHT HINGE LEFT HINGE SHIELD PLATE SHAFT MOUNT BLOCK MOUNT BRACKET STANDOFF UPPER EXIT GUIDE LOWER EXIT GUIDE PARTS SECTION I PAGE 51 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 52 002D 17812 TRANSPORT CONVEYOR PAGE 2
83. 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 186 37123612 186 37123614 186 37123299 186 3790100500 186 379010050 186 37CD40105 186 37CD40005 186 37123607 186 37123237 186 37123601 186 37CD30106 186 37CD30006 186 37123913 186 37CD40118 186 37123690 186 37CD40018 186 37CD30023 186 37123680 186 37123725 186 37123089 186 37123301 186 37CD30025 186 37CD30032 186 37123252 186 37CD30022 186 37CD40009 186 37CD40003A 186 37123620 186 375050041 SCREW 6 32 X 25 SCREW 6 32 X 50 SPACER P C BOARD P C BOARD before s n 51284 ELECTRICAL CABINET ELECT CAB before s n 51284 WIRE CLAMP STAR 10 MOTOR PULLEY 14XL MOTOR BRACKET MOTOR BRKT before s n 51284 MOTOR MOTOR ASSEMBLY MOTOR before s n 51284 MOTOR ASM before s n 51284 WIRE HARNESS FUSE SWITCH FUSE 5A 250V 115V 60HZ FUSE 25A 250V 115V 50HZ FUSE HOLDER STRAIN RELIEF POWER CORD FUSE SHIELD STAR WASHER 6 WIRE HARNESS TRANS SWITCH CENTER SUPPORT CONVEYOR BODY RUBBER FOOT table top model IDLER ROLLER PARTS SECTION I PAGE 61 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 62 706 25697 400 T J LINE CODE READ OPTION
84. 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 010 STA 00 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 PROBLEM ANALYSIS SECTION C PAGE 13 SMART FEEDER SERVICE MANUAL 07 on a six station inserter PT xx selects the postal meter output line to the 420 this is normally set to 9 6 Logical Shift is normally set to ENABLE at 090 This is used to carry the data with the physical document 7 Bad Package Stop is normally set to ENABLE at 080 8 Number of Insert Stations should be selected to match your inserter configuration IMPORTANT Number of Empty Stations must be set correctly for Postal Meter Weighing to work correctly 9 Number of Empty Stations are the number of stations that do not have inserters This would be the space taken by the 420 usually 02 10 Encoder Type select your encoder type 11 Opto Logic Type select your type 12 Postal Meter 2 see Postal Meter 1 PT xx is usually set to 01 13 Not Used 14 Postal Meter 3 see Postal Meter 1 PT xx is usually set to 02 15 Postal Meter Weights should be set to the upper weight limit of Postal Meter 1 for METER 1 to 2 00000 and the upper weight limit of Postal Meter 2 for METER 2 to 3 00000 16 Weight Page and Envelope should be set to the weight of a single sheet from
85. 9 12VDC and 12VDC power PS1 3 Solid State Relays SSR For switching high 6 24 VDC Power Supply PS1 power items motors etc SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 81 E PRINTED WIRING BOARD INFORMATION E 2 CONNECTOR DESIGNATIONS E 3 Printed wiring boards PWB E 3a Introduction ite hee iss E 3b Specifications eee tarte tert eaten E 3c Functional description Board back side of panel containing opto racks SMART FEEDER SERVICE MANUAL ISS KBIC Board control motor speed Display Board PWB Locations Figure E 1 UE 09 00 PRINTED WIRING BOARDS SECTION E PAGE 1 CPU 186 Board SBX Board Reader Board Preamplifier Board Opto Racks 0 and 1 SMART FEEDER SERVICE MANUAL E 2 CONNECTOR DESIGNATIONS CPU 186 I O CONNECTORS STD BUS EDGE CONNECTOR To Opto Rack 1 via SBX Board RS 232 1 To Display RS 232 COM2 ISSUE 09 00 RS 232 COM3 J6 RS 232 4 RS485 COM3 To Encoder via Pin 7 Opto 5 Rack 0 RS 485 COM4 COUNTER TIMER INTERFACE To Opto Rack 0 Preamplifier Board to Read Sensor to CN2 of Reader Board Reader Board To J1 of SBX Board to CN2 of Preamplifier Board to reader power cable to 5VDC power and Alarm Bell 1 J2 to J4 of CPU 186 Board PRINTED WIRING BOARDS SECTION E PAGE 2 SBX Board JO
86. 9 CHOOSE TYPE PRE FEEDER CONVEYOR TYPE PRE FEED CONV lt gt UNDO EXIT SMART FEEDER SERVICE MANUAL ISSUE 09 00 FEED BRAKE DISABLE ENABLE PROBLEM ANALYSIS SECTION C PAGE 7 SMART FEEDER SERVICE MANUAL 1 18 Two Sheet Detect Disable is normally set to ON but can be turned off if varying thickness stock is being run or if printing on the stock is affecting the double detect sensor 2 18 EXIT CONTROL is normally set 1070 0 Standard Inserter Control 1 12Bit Control preliminary 2 8Bit Collector Control preliminary 3 18 Lower Left Display can be customized to the operator s preference 4 18 Lower Right Display can be customized to the operator s preference 5 18 No Use Shutdown Time Length sets the time the Smart Feeder will run without being used before it cycles down 6 18 Pulse Feeding Enable is normally turned OFF When turned ON the feeder will place a larger gap between the sheets being fed 7 18 Choose Type Transfer Conveyor is normally set to GRIPPER ARM when the inserter will be taking the folded document from the Smart Feeder Select HOPPER FILL when the inserter will be taking the folded documents from a hopper Select OPEN FEED when the Smart Feeder will be placing the folded documents directly on the inserter track 8 18 Display Bell Disable is normally set to ON Turning this OFF will turn the bell on the Smart Feeder display off ISSUE 09 00 PROBLEM ANALYSIS SECTION C PA
87. ACKAGES PER HOUR 3 CYCLE ENTIRE SYSTEM CYCLING SYSTEM UNDO EXIT SIMULATING 10 000 PACKAGES PER HOUR 4 CYCLE TRANSFER CLUTCH BRAKE CYCLE TRANSFER CONVEYOR UNDO EXIT SIMULATING 10 000 PACKAGES PER HOUR Scroll through the choices within the option and press ENTER to accept SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 11 SMART FEEDER SERVICE MANUAL TIMING SELECT TIMING TO SET lt gt ENTER 1 INSERT VACUUM ISSUE 09 00 INSERT VACUUM ENABLE AT 100 ENVELOPE HOPPER VACUUM ENVELOPE HOPPER VACUUM UNDO EXIT ON AT 230 Insert Sta 2 ENVELOPE FLAP DETECT ENVELOPE FLAP DETECT UNDO EXIT ON 010 OFFAT 350 Insert Sta 1 INK MARKING INK MARK UNDO EXIT ON AT 010 OFF AT 180 STA AT 00 POSTAL METER DIVERT 1 ONat 200 OFFat 010 STA 07 PT 09 LOGICAL SHIFT LOGICAL SHIFT UNDO EXIT ENABLE AT 090 BAD PACKAGE STOP UNDO EXIT 11 PROBLEM ANALYSIS SECTION C PAGE 12 SELECT ENCODER TYPE UNDO EXIT B amp H ROTATIONAL POSITION BOX 36 TICK REV GBR 100 TICK ENCODER OPTO LOGIC TYPE SELECT OPTO TYPE UNDO EXIT AC DC DUMB INSERTER LEFT HAND CONTROL CARD 775 BAD PACKAGE STOP UNDO EXIT ENABLE AT 080 NUMBER OF INSERT STATIONS GRIPPER LAYOUT UNDO EXIT 4 6 4 4 6 4 4 6 654321 NUMBER OF EMPTY STATIONS MUST ENTERED NUMBER OF EMPTY STA UNDO EXIT STATIONS 02 ENCODER TYPE 12 POSTAL METER2 ONat 24
88. AGE 71 SMART FEEDER SERVICE MANUAL D 7e2 POSITION FOLD PLATE fH NOTE If it is determined fold plate 1 should not perform a fold continue with step 10 If fold plate 1 will perform a fold skip step 10 and go directly to step 11 10 Insert the deflector end of fold plate 1 into the folder Make sure that fold plate 1 rests on the fold plate stops GO TO STEP 15 11 Loosen the thumb screw on the Fold Stop 12 Slide the Fold Stop so its front edge lines up with the appropriate setting on the Left and Right Fold Plate Scales for fold plate 1 13 If necessary adjust the Fold Stop Level thumb wheel until the measurement on each of the fold plate scales is exactly the same 14 Insert the open end of fold plate 1 back into the folder making sure that the fold plate rests on the fold plate stops ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 72 D 7e3 POSITION FOLD PLATE 2 NOTE if it is determined fold plate 42 should not perform a fold continue with step 15 If fold plate 2 will perform a fold skip step 15 and go directly to step 16 15 Insert the deflector end of fold plate 2 into the folder Make sure that fold plate 42 rests on the fold plate stops GO TO STEP 21 16 Loosen the thumbscrew on the Fold Stop 17 Slide the Fold Stop so its edge lines up with the appropriate setting on the Left and Right Fold Plate Scales for fold plate 2 18 Tighten the Fold Stop thumb wheel 19 If necessa
89. AL PROBABLY SOLENOID 75 PUR NUES CONNECTION BETWEEN FLAP DETECT ERROR CIRCUIT AND GROUND BREAK CONNECTION CONNECT TO POINT WITH GREATEST POSITIVE POTENTIAL WHT BLK BLU OTHER SIDE OF CONNECTION BROKEN ABOVE MUST BE CIRCUIT GROUND SEE NOTE 2 WHT BLK VIO QUIT CR TU CONNECTION BETWEEN ENVELOPE CONTROL SWITCH AND ENVELOPE SOLENOID BREAK CONNECTION CONNECT TO SWITCH CONNECT TO POINT WITH GREATEST POSITIVE POTENTIAL PROBABLY SWITCH LK GR OTHER SIDE OF CONNECTION BROKEN ABOVE C GROUND r CATEST NEGATIVE POTE map IA CONNECT TO SOLENOID CONNECT TO POINT WITH GREATEST NEGATIVE POTENTIAL PROBABLY SOLENOID WAT DLA YE CONNECT THESE TWO WIRES ACROSS POINT IN THE CIRCUIT THAT WILL PROVIDE VOLTAGE WHEN CONNECT TO POINT WITH GREATEST POSITIVE POTENTIA HE INSERTER IS RUNNING En OT WHT BLK RED CONNECTION BETWEEN STATION 1 CONTROL SWITCH AND STATION 1 SOLENOID BREAK CONNECTION CONNECT TO SWITCH CONNECT TO POINT WITH GREATEST POSITIVE POTENTIAL PROBABLY SWITCH CIE P a OTHER FO 0 0 m CONNECT TO SOLENOID CONNECT TO POINT WITH GREATEST NEGATE POTENTIAL PROBABLY SOLENOID RED GRN gt CONNECT THESE TWO WIRES IN SERIES WITH STATION 1 ERROR DETECT SWITCH SEE NOTE 3 CONNECT TO POINT WITH GREATEST POSITIVE POTENTIA m CONNECT TO POINT WITH GREATEST NEGATIVE POTENTIAL NO CONNECTION WHT RED RED m 4 WHT RED BLK WHT RED GRN NOTE 1 GENERAL NOTE F
90. ANGER Tus LASER RADIATION WHEN OPEN miti 47 AVOID DIRECT EXPOSURE CAUTIONS bs MODEL 30 gt tif 222 Top View FLIP DOWN TO SHUT OFF LASER AVOID EXPOSURE LASER RADIATION EMITTED FROM THIS APERTURE u DANGER 2 LASER LIGHT WHEN OPEN 1 AVOID DIRECT EXPOSURE saa USTED 8 TUS Front View Side Standard Laser Caution Labels REPAIR INFORMATION SECTION D PAGE 53 SMART FEEDER SERVICE MANUAL D 5b 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 position orientation or type of bar code changes Quie 420 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 ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 54 spaces The basic co
91. BRACKET CLAMP COLLAR GEAR PLASTIC SPUR CONVEYOR DRIVE SHAFT SHAFT SHAFT CONVEYOR SUPPORT ISSUE 12 00 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 600A 17700 600C 17708 600C 17709 600D 17724 600B 18634 600C 18633 600B 18647 600E 18632 600A 17733 600A 17734 600A 17735 600B 18637 600A 17785 600A 18639 600B 18702 600D 18035 600B 18108 600B 18109 600C 18716 600B 18636 600B 18640 600A 18568 020 HS31020830 600B 19304 600B 19305 DRIVE PULLEY RIGHT RAIL LEFT RAIL LEFT SIDE PLATE CONVEYOR SHIELD CONVEYOR SHIELD SUPPORT BAR COVER COLLAR GEAR RIGHT PIVOT STOP INFEED GUIDE LEFT PIVOT STOP SHAFT INFEED GUIDE RIGHT SIDE PLATE RIGHT HINGE LEFT HINGE SHIELD PLATE SHAFT MOUNT BLOCK STANDOFF UPPER EXIT GUIDE LOWER EXIT GUIDE PARTS SECTION I PAGE 55 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 56 002D 18652 11 TRANSPORT CONVEYOR PAGE 2
92. COMMAND Unexpected signal BAD READ Misread document PAGE OUT OF SEQUENCE roll sequence out of order in bar code MAX NOT NO PAGES Incorrect page count in accumulator GROUP SEQUENCE ERROR Group out of sequence N GROUP CHANGED IN SET Group out of sequence II SS ONS ou Q 02 PROBLEM ANALYSIS SECTION C PAGE 20 Incorrect user input Bad CPU 186 board Blank CPU 186 board Check clean and adjust scanner Incorrect user input Bad CPU 186 board Blank or bad bar code Check clean and adjust scanner Incorrectly printed document Documents out of order Code not seen Check clean and adjust scanner Battery jumper removed from CPU 186 Bad CPU 186 board Page count setting incorrect EOG mark not seen Read error Customer ID changed in the middle of a ckage Incorrectly printed document Documents out of order Code not seen Check clean and adjust scanner Incorrectly printed document Documents out of order Code not seen Check clean and adjust scanner SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 21 SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 22 ROLL 7 OUT OF SEQ Roll sequence out of order Incorrectly printed document Documents out of order 3 Code not seen 4 Check clean and adjust scanner EXPEC
93. CTOR 4 600A 21880 SENSOR BRACKET 5 600A 21881 ADJUSTABLE SUPPORT 6 600A 22671 MOUNTING BLOCK 7 600A 22672 MOUNTING PLATE SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 79 SMART FEEDER SERVICE MANUAL ISSUE 12 00 002K 08432 INSERTER DEMAND SWITCH KIT PARTS SECTION I PAGE 80 ACKET ONLY USED IF LC SERTER 002K 23756 INK MARKER OPTION BELL amp HOWELL INDEX PART NUMBER DESCRIPTION 1 002B 07186 INK MARKER INTERFACE CABLE 2 002B 07187 SENSOR INPUT MODULE 3 002B 07188 MODULE 9 INTERFACE CABLE 4 002B 23702 SENSOR ASSEMBLY 5 002C 07200 INK MARKER CONTROL BOX 6 007 24265 600 HOLD DOWN BRACKET SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 81 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 82 002K 07970 AC DC INSERTER CONTROL OPTION Jo vol 5
94. D ENCODER CABLE 3 002B 08407 LINE CODE SENSOR 4 002B 18518 ENCODER ASSEMBLY 5 002B 19351 TOP PROBE MOUNTING BAR 6 002B 19352 BOTTOM PROBE MOUNT 7 002C 08013 S CHANNEL D PROBE PLATE 8 002C 08101A SINGLE CHANNEL READ BOARD 9 002C 08104 OMR FIBER SENSOR ASSEMBLY 10 002B 19353 READ BLOCK 11 007 26389 600 BRACKET 12 024 26390 600 DIN RAIL 13 026 ABMMA TIE WRAP ANCHOR 14 026 PLT1MM TIE WRAP 15 140 02500170E2 TUBING 25 3 LONG 16 600A 18374 PULLEY 17 600A 18378 BELT 18 600A 19261 SENSOR MOUNT 19 057 FT500 SENSOR FIBER 20 186 330525774 SENSOR SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 65 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 66 002K 20772 BAR CODE READER 3 OF 9 00K 20772 BAR CODE READER 3 OF 9 INDEX PART NUMBER 002A 20916 002A 20917 002B 07757 002D 20739 002D 20746 600D 20727 600D 20728 NOOR WD DESCRIPTION UPPER PAPER GUIDE LOWER PAPER GUIDE SCANNER CABLE LASER SCANNER ASSEMBLY SINGULATOR COVER LEFT PAPER GUIDE RAIL RIGHT PAPER GUIDE RAIL SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 67 SMART FEEDER SE
95. EDER IS TOO FAST 1 Feed motor KBIC out of adjustment STATE DIDN T CHANGE Feeder software routines could not finish a task 1 State of feed sensor incorrect ON should be OFF or vice versa HOPPER EMPTY JAM An attempt to feed a document failed 1 The singulator feeder belts are improperly adjusted 2 The hopper is out of paper CUTTER JAM BUSY Cutter is busy for more than 2 seconds Check cutter for jammed document Check connections to cutter CUTTER JAM READY Cutter did not respond with a busy signal Check cutter for jammed document Check connections to cutter CUTTER JAM SENSOR Cutter detects a jammed document 1 Check cutter for jammed document 2 Check connections to cutter SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 27 SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 28 PRESETS CORRUPT Memory values out of range 1 Battery jumper removed from CPU 186 Battery failed or battery jumper missing 3 Bad CPU 186 board DOC JAMMED INSIDE Folder jam a document has not exited the folder 1 A document has jammed inside the folder in time A buckle plate is open The out from folder is out of adjustment The out from folder sensor has failed STALL JAM EXITING Folder jam a document has not exited the folder 1 A document has discharge sensor in time A buckle plate is open The out from folder sensor is out of adjustment The out from folder sensor has failed S
96. EDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 100 750 26978 500 3208 FEEDER ELECT INTERFACE PAGE 1 INDEX PART NUMBER DESCRIPTION 1 020 01020636 STANDOFF 10 32 X 3 2 032 00080250 FUSE 8 AMP 250V SB 3 045 022115 WIRE GRN 22 GA 4 091 27411 500 ADAPTOR PLATE ASM 5 526 27407 500 LINE CORD ASSEMBLY 6 526 27408 500 CABLE 470 INTERCONNECT 7 526 27409 500 CABLE E STOP 8 526 27511 500 CABLE AUTO MODE 9 750 26978 500 470 FEEDER MECH ASSEMBLY 750 27576 500 3208 FEEDER ELECT INTERFACE PAGE 2 L 6 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 101 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 102 750 26978 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 CABLE E STOP 10 526 2751 1 500 CABLE AUTO MODE 11 750 26978 500 470 FEEDER
97. EEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 30 002D 19017 ACCUMULATOR PAGE 1 002D 19017 ACCUMULATOR PAGE 1 INDEX PART NUMBER DESCRIPTION 1 002A 17927 BEARING BLOCK 2 002B 08157 BRAKE 3 002B 08445 INTERLOCK 4 002B 16342 DRIVE ROLLER 5 002B 16767 PULLEY 6 002B 17806 DUMP SHAFT 7 002B 19014 CLUTCH SHAFT ASSEMBLY 8 002B 23963 SENSOR 9 002D 08156 KEYBOARD ASSEMBLY 10 014 05021108 SHCS 5 40 X 5 11 016 105 WASHER LOCK 5 12 016 710 WASHER TRAP 13 020 RA006C0603 STANDOFF 14 112 200DOA24637 PULLEY TIMING 24T 15 112 200DOA25637 PULLEV TIMING 25T 16 158 S3PPB5ST RADIAL BEARING 17 181 3600401000 SPRING 18 332 301870107 ST STL SHAFT 19 600B 17023 ST STL SHAFT 20 600A 15915 025 ADJUSTMENT SCREW 21 600A 16349 020 DRIVE ROLLER 22 600A 16962 BEARING 23 600A
98. EPAIR INFORMATION SECTION D PAGE 8 D 2c4 Setting Main Feed Belt Tension The Feed Belt provides the primary force separating a sheet from the bottom of the shingled stack The setup procedure for this belt is described below The Feed Belt tension adjustment knob is factory set limited to approximately 3 4 turn This is adequate operator adjustment for typical paper weight variations If the Feed Belt is replaced 1 Loosen the long set screw 3 32 on the top stop collar of the Feed Belt tension knob shaft 2 Lay a straight edge across the top of the Feed belt lengthwise Make sure it lays across both pulleys 9 Adjust the Feed Belt tension knob so 3 16 inch Feed Belt deflection is possible in the middle of 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 pu mik 8 ca L Y 157 157 limit adjustment to 3 4 turn Belt Adjust Figure D 2c5 Singulating Roller The singulating Roller creates a precise singulating gap There are three critical adjustments required to get
99. GE 8 9 18 Choose Type Pre Feeder Conveyor is normally set to CREEPER ONLY 10 18 High Count is normally set at 7 High Count allows the operator to define the number of documents in a group which will trigger a required stop Operator can then process the group manually This might be used to accommodate odd groups in metered mail applications Press the TEST button Scroll to SETUP Press ENTER button Scroll to feature 10 of 10 HIGH COUNT STOP Press ENTER button Menu will display HIGH COUNT STOP This parameter should be set to 7 from the factory but can range from 1 to 10 Use settings greater than 7 only when processing V folds 6 Enter the number of documents representing the highest total documents in a group 7 Press ENTER When the SmartFeeder accumulates the set number of documents and recognizes that it is not the end of a group the machine will stop and an error message will be displayed MAX PAGES IN ACCUM single cycle MAX SHEETS IN ACCUM auto cycle AI Remove the document packet and reset the machine to resume operation Process the removed packet manually If the error occurs but the document packet is correct make sure the High Count Stop is set to the proper value see above 11 18 Performance OFF is the normal setting however if increased throughput of the Smart Feeder is needed to maintain the speed of the interfaced unit then Performance ON should be selected If this
100. GROUND 186 COUNTER 1 INPUT O O 186 TIMER 1 OUTPUT U4 COUNTER INPUT O OL ya TIMER OUTPUT CONNECTOR PINS FACING UP J9 Counter Timer Connector Pinout Figure E 5 PRINTED WIRING BOARDS PORT CBIT 7 1 PORTBBITO O PORTABIT7 PORTABITO o 5406 f 49 SECTION E PAGE 10 Parallel DO PIO Interface J10 J10 is a 50 pin connector with 24 PIO pins controlled by an on board 8255 It can be connected directly to an OPTO 22 module with a 50 pin ribbon cable The following illustrates the pinout of J10 2 SHOWN WITH PINS FACING UP 910 Parallel Connections figure E 6 SMART FEEDER SERVICE MANUAL ISSUE 09 99 PRINTED WIRING BOARDS SECTION E PAGE 11 SECTION F MACHINE SCHEMATICS Schematic Page 002 08111 SHEET 1 of 5 2 Main Power Power Unit Feeder Power Folder Power 8 Slot Card Cage Power 002E 08111 SHEET 2 of 5 3 Keyboard Emergency Stop Feeder Folder 002 08111 Sheet 3 of 5 4 Opto Racks Display Assembly Inserter Module 7 Cable 002 08111 Sheet 4 of 5 9 Transfer Conveyor Straight Conveyor FIMA 2000 Interface 470 3208 Feeder Accumulator Ink Marker 002 08111 Sheet 5 of 5 6 First Page Hold FIMA 2000 002K 08133 Sheet 4 of 4 7 6 Station Inserter 002C 07968 8 Sensor Interconnect Cable SMART FEEDER SERVICE MANUAL ISSUE 09 00 MACHINE SCHEMATICS BIK BIK
101. HAFT BEARING DRIVE PULLEY RIGHT RAIL SUPPORT LEFT RAIL SUPPORT LEFT SIDE PLATE RIGHT PIVOT STOP LOWER CONVEYOR BELT UPPER IDLER BELT LOWER NIP DRIVE BELT UPPER CONVEYOR BELT LOWER EXIT BELT UPPER EXIT BELT DRIVE SHAFT LEFT PIVOT STOP PAPER GUIDE RIGHT SIDE PLATE SHAFT PARTS SECTION I PAGE 53 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 54 002D 18652 11 TRANSPORT CONVEYOR PAGE 1 002D 18652 11 TRANSPORT CONVEYOR PAGE 1 INDEX PART NUMBER Q O OQ Q N 11 12 13 14 15 16 17 18 19 20 21 22 23 24 SMART FEEDER SERVICE MANUAL 002B 08408 002B 08413 002D 08434 002B 08457 002B 08463 002B 08486 002B 08487 002A 18044 002C 18717 002B 19599 002B 08409 600B 18635 041 35701 112 200D0A25637 112 S6A320H3712 112 S6A320NF037 113 200180037 113 200220037 113 200230037 600A 18654 600A 16342 001 600A 16349 031 600B 18644 600B 18649 600B 18646 600B 17695 DESCRIPTION BRAKE MAGNETIC EXTENSION TRANSPORT CONVEYOR ELECT CENTER SENSOR END SENSOR DISCHARGE SENSOR PACKAGE PRESSURE SENSOR PULLEY CONVEYOR COVER CLUTCH SHAFT ASSEMBLY CLUTCH ONLY SHAFT ONLY INTERLOCK MAGNET PULLEY TIMING 25T PULLEY TIMING 20T PULLEY TIMING 20T BELT TIMING BELT TIMING BELT TIMING SENSOR
102. IDE RAIL LEFT PAPER GUIDE RAIL RIGHT FEEDER TRAY STATIC BRAID GROUND WIRE 002E 19047 FEEDER ASSEMBLY PAGE 2 __ D Y IA ES EWE 20 SMART FEEDER SERVICE MANUAL ISSUE 09 00 PARTS SECTION I PAGE 15 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 16 002E 19047 FEEDER ASSEMBLY PAGE 2 INDEX PART NUMBER DESCRIPTION 1 002A 16437 PULLEY 2 002B 08526 MOTOR 3 002B 22221 PULLEY 4 002D 16435 SINGULATOR 5 002D 18099 SINGULATOR COVER 6 057 25971 500 SENSOR 7 095 25212 600 SHAFT 8 144 26616 600 PLASTIC STRIP 9 112 200DBA16637 PULLEY TIMING 16T 10 112 200DBA18650 PULLEY TIMING 18T 11 112 200DBA30637 PULLEY TIMING 30T 12 112 200DBA32637 PULLEY TIMING 32T 13 113 20008003712 BELT TIMING 14 113 200090037 BELT TIMING 15 113 200290037 BELT TIMING 16 122 25211 500 FRICTION CLUTCH 17 153 FB6103 FLANGE BEARING 18 181 3000401000 SPRI
103. IPTION OF CONNECTION NOTES FOR INSERTERS WITH D C CONTROL BL CONNECTION BETWEEN STATION 2 CONTROL SWITCH AND STATION 2 SOLENOID BREAK CONNECTION CONNECT TO SWITCH CONNECT TO POINT WITH GREATEST POSITIVE POTENTIAL PROBABLY SWITCH BR OTHER SIDE OF CONNECTION BROKEN ABOVE ONNECT CATEST NEGATIVE POTENTI CONNECT TO SOLENOID CONNECT TO POINT WITH GREATEST NEGATIVE POTENTIAL PROBABLY SOLENOID OR gt CONNECT THESE TWO WIRES IN SERIES WITH STATION 2 ERROR DETECT SWITCH CONNECT TO POINT WITH GREATEST POSITIVE POTENTIA 7 CONNECT TO POINT WITH GREATEST NEGATIVE POTENTIA 7 CONNECTION BETWEEN STATION 3 CONTROL SWITCH AND STATION 3 SOLENOID BREAK CONNECTION CONNECT TO SWITCH CONNECT TO POINT WITH GREATEST POSITIVE POTENTIAL PROBABLY SWITCH ER SIDE VF CONNECT TO SOLENOD CONNECT TO POINT WITH GREATEST NEGATIVE POTENTIAL PROBABLY SOLENOID m gt CONNECT THESE TWO WIRES IN SERIES WITH STATION 3 ERROR DETECT SWITCH CONNECT TO POINT WITH GREATEST POSITIVE POTENTIA E CONNECT TO POINT WITH GREATEST NEGATIVE POTENTIA CONNECTION BETWEEN STATION 4 CONTROL SWITCH AND STATION 4 SOLENOID BREAK CONNECTION CONNECT TO SWITCH CONNECT TO POINT WITH GREATEST POSITIVE POTENTIAL PROBABLY SWITCH CINE ABOVE m CONNECT TO SOLENOID CONNECT POINT WITH GREATEST NEGATIVE POTENTIAL PROBABLY SOLENOID JPL _ o u WHT BR gt CONNECT THESE TWO WIRES IN SERIES WITH STATION 4 ERROR DETECT SWITCH CONNECT POINT WITH GREATEST
104. LE DEMAND 12 526 26313 500 CABLE 90 DEGREE CUTTER 13 526 26414 500 CABLE 420 TO BOWE 14 526 26315 500 CABLE 420 TO 90 DEGREE 15 526 26316 500 CABLE 24VDC POWER 16 526 26317 500 CABLE BOWE STOP RELAY NOTES SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 105
105. MART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 49 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 50 002D 17812 TRANSPORT CONVEYOR PAGE 1 002D 17812 TRANSPORT CONVEYOR PAGE 1 INDEX PART NUMBER 1 002B 08408 2 002B 08413 3 002D 08434 4 002B 08457 5 002B 08463 6 002B 08486 7 002B 08487 8 002A 18044 9 002C 18243 10 002B 18850 002B 08409 600B 18620 11 041 35701 12 112 200DBA25637 13 112 S6A320H3712 14 112 S6A320NF037 15 113 200180037 16 113 200220037 17 113 200230037 18 152 B187125 19 600A 16342 001 20 600 16349 031 21 6008 17684 22 6008 17693 23 6008 17694 24 6008 17695 SMART FEEDER SERVICE MANUAL DESCRIPTION BRAKE MAGNETIC EXTENSION TRANSPORT CONVEYOR ELECT CENTER SENSOR END SENSOR DISCHARGE SENSOR PACKAGE PRESSURE SENSOR PULLEY CONVEYOR COVER CLUTCH SHAFT ASSEMBLY CLUTCH ONLY SHAFT ONLY INTERLOCK MAGNET PULLEY TIMING 25T PULLEY TIMING 20T PULLEY TIMING 20T BELT TIMING BELT TIMING BELT TIMING BUSHING NYLON CLAMP COLLAR GEAR PLASTIC SPUR CONVEYOR DRIVE SHAFT SHAFT SHAFT CONVEYOR SUPPORT ISSUE 1
106. ME GUIDE BUSHING TRACK BUTTON INSERT ADJUSTMENT SCREW TRACK BUTTON WORM CLAMP COLLAR TENSION ADJUST ISSUE 09 00 PARTS SECTION I PAGE 19 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 20 547 25938 500 RIGHT SIDE CHASSIS ASSEMBLY 12 NS 1 A AN 3 ND 10 kas e 1 2 0 Hi 2 m 547 25938 500 RIGHT SIDE CHASSIS ASSEMBLY INDEX PART NUMBER 1 002A 17929 2 002B 08569 3 016 712 4 019 100062 5 158 S3PPB5ST 6 173 2194 7 181 3600401000 8 547 25935 600 9 600A 15839 012 10 600A 15839 119 11 600A 15915 025 12 600A 17921 13 600B 15839 068 14 600A 18200 15 020 RAO1020632 SMART FEEDER SERVICE MANUAL DESCRIPTION BEARING BLOCK INTERLOCK ASSEMBLY CUP WASHER E RING RADIAL BEARING BUMPER SPRING RIGHT FRAME GUIDE BUSHING TRACK BUTTON INSERT ADJUSTMENT SCREW GROUND SCREW TRACK BUTTON CLUTCH STOP STANDOFF 10 32 X 2 ISSUE 09 00 PARTS SECTION I PAGE 21 PARTS SMART FEEDER SERVICE MANUAL ISSUE 12 00 SECTION I PAGE 22 002D 16435 SINGULATOR ASSEMBLY lan MA m N _ _ A j 1 ry LOWER Y 13 IN S lt V Sn d
107. NG 19 547 25938 500 RIGHT CHASSIS ASSEMBLY 20 600A 16122 030 RAIL STIFFENER 21 600A 16556 WORM GEAR 22 600A 17661 DRIVE SHAFT 23 002B 19351 TOP PROBE MOUNT 24 600A 18699 ANTI TORSION BLOCK 25 600A 18700 ADJUSTMENT BLOCK 26 600A 21521 MOUNT BLOCK 27 600B 16122 033 HOPPER FEED SHAFT 28 600B 17045 UPPER SHAFT 29 600B 17228 MOUNT BLOCK 30 002B 19352 BOTTOM PROBE MOUNT 31 600B 19690 GUIDE SHOE 32 600B 22223 ADAPTOR PLATE SMART FEEDER SERVICE MANUAL ISSUE 09 00 PARTS SECTION I PAGE 17 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 18 547 25937 500 LEFT SIDE CHASSIS ASSEMBLY it ES X A z 55 Z lt lt ur Z ui 7 3 9 N z C 5 547 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 S3PPB5ST 7 173 2194 8 181 3600401000 9 547 25934 600 10 600A 15839 012 11 600A 15839 119 12 600 15915 025 13 600B 15839 068 14 104 1M5N25 15 126 SSC25 16 600B 17666 SMART FEEDER SERVICE MANUAL DESCRIPTION BEARING BLOCK HEX NUT 10 24 SHOULDER BOLT CUP WASHER E RING RADIAL BEARING BUMPER SPRING LEFT FRA
108. ONTROLLER ISSUE 12 00 PARTS SECTION I PAGE 27 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 28 002D 17505 CREEPER CONVEYOR 002D 17505 CREEPER CONVEYOR INDEX PART NUMBER DESCRIPTION 1 002B 09341 CREEPER MOTOR 2 002B 16631 FRONT SHAFT ASSEMBLY 3 002B 16633 MOTOR MOUNT PLATE RIGHT 4 002B 16634 MOTOR MOUNT PLATE LEFT 5 016 525 WAVY WASHER 6 112 200DBA15625 MOTOR DRIVE PULLEY 7 113 200500037 CONVEYOR BELT 8 113 200070037 DRIVE BELT 9 126 SSC25 SET SCREW COLLAR 10 172 1039A1032 HANDLE 11 600 15841 009 DRIVE SHAFT 12 600A 15841 011 SHAFT 13 600A 15841 015 STACK GUIDE LOCK ECCENTRIC 14 600B 15841 017 IDLER ROLLER SHAFT BRACKET 15 600A 15841 020 HANDLE 16 600A 15841 021 IDLER STUD 17 112 200 14638 PULLEY 14T 18 600 16651 ROLLER 19 600 16652 ROLLER 20 600B 15841 014 TENSION BAR 21 600B 15841 019 LOCK ANGLE 22 600B 15917 005 MYLAR COVER 23 600C 15841 001 BED 24 600C 16575 001 STACK GUIDE LEFT 25 600C 16575 002 STACK GUIDE RIGHT 26 600C 17771 REAR CREEPER COVER SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 29 SMART F
109. OR INSERTERS WITH A C CONTROL CONTROL VOLTAGES MUST 12 280VAC 002C 07968 NOTE 2 ASSUMES THAT FLAP DETECT CIRCUIT CONNECTS TO CIRCUIT GROUND TO CREATE AN ERROR SENSOR INTERCONNECT CABLE NOTE 3 ONLY MAKE STATION 1 CONNECTIONS IF 420 PF300 IS NOT LOCATED AT STATION 1 LE OPEN ENDED NOTE THIS SHEE gt INSTALLATION INSTRUCTIONS SECTION G INSTALLATION The 420 is designed to be run on line with the inserter It can G REMOVAL OF HOPPER SIDE PLATES 2 G 2 REMOVE HOPPER GUIDE 2 be docked to any of the insert stations however station 1 is REMOVE SINGULATOR FINGER 3 preferable Before the 420 may be mated up to the Inserter 4 420 INTERFACE COUPLING 4 there are a few pieces on the Inserter which need to be G 5 TRANSFER CONVEYOR ADJUSTMENITS 6 removed or repositioned The parts to be removed are the G 5A PACKAGE OVERHANG AT LAST esee 6 hopper side and rear plates T plate and insert cushion cup G 5B POSITION OF THE OUTFEED GUIDES aa 6 G 5C FOLD OVALI V SC e etes a 6 The singulator finger and cushion cup mount must be G 5D IF A PACKAGE SPACING PROBLEM 6 repositioned A dema
110. PT CABLE ENCODER INTERRUPT CABLE ISSUE 12 00 SECTION I PAGE 10 002D 08135 POWER UNIT A C BOX
111. R CABLE 4 002C 08495 005 POWER CABLE 5 002D 08135 POWER UNIT ASSEMBLY 6 002D 08137 CONTROL PANEL ASSEMBLY 7 005 25960 500 CABINET 8 041 4LTGUO511TR ROCKER SWITCH 9 172 CR7300 LOCK WITH KEY 10 173 1072314 VIBRATION MOUNT SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 7 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 8 002D 08137 CONTROL PANEL ASSEMBLY 002D 08137 CONTROL PANEL ASSEMBLY 18 ARS N
112. R IDLER SHAFT IDLER SHAFT BEARING DRIVE PULLEY RIGHT RAIL SUPPORT LEFT RAIL SUPPORT LEFT SIDE PLATE RIGHT PIVOT STOP LOWER CONVEYOR BELT UPPER IDLER BELT LOWER NIP DRIVE BELT UPPER CONVEYOR BELT LOWER EXIT BELT UPPER EXIT BELT DRIVE SHAFT LEFT PIVOT STOP PAPER GUIDE RIGHT SIDE PLATE SHAFT PARTS SECTION I PAGE 57 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 58 002E 19056 STRAIGHT CONVEYOR PAGE 1 por a all IT 1 p amy 9 RE l T 10 EN NAS N gt I N Nil SSE x V u l 4 AN A A HAL at 9 ZN M N a E 4 im a m ve 5 002E 19056 STRAIGHT CONVEYOR PAGE 1 INDEX PART NUMBER 002D 08053 002B 08570 002B 19404 124 15914 600A 18855 600A 19057 600A 19058 186 031027342 186 032012468 186 034001925 186 034003980 SMART FEEDER SERVICE MANUAL DESCRIPTION EXIT
113. ROLLER TRACTOR BELT Replaced by 118 30307 600 PULLEY BUSHING AXLE SMART FEEDER SERVICE MANUAL ISSUE 09 00 PARTS SECTION I PAGE 25 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 26 002D 08522 FEEDER ELECTRICAL ASSEMBLY n L i L 81 Lj 5 EST N SN J NES c y ET Nec E 13 u MA 002D 08522 FEEDER ELECTRICAL ASSEMBLY INDEX PART NUMBER O GQ N SMART FEEDER SERVICE MANUAL 002B 07741 002B 07742 526 26634 500 002D 08522 001 002D 08522 003 002D 08522 004 002B 08662 024 1401019 030 1240025 032 003 8250 032 10120250 047 S9841 050 20VDK1 054 KBIC125 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 AMP FUSE 12 AMP RESISTOR LINE FILTER MOTOR C
114. RVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 68 002D 20739 LASER SCANNER ASSEMBLY at 002D 20739 LASER SCANNER ASSEMBLY INDEX PART NUMBER 002 16496 009 O O1 GQ N 026 1200 088 01MRB01302 332 375 600A 20700 600A 20770 600A 20771 600A 20830 600A 20831 600A 20832 600A 20836 600A 20849 600B 20703 600B 20769 600C 20701 600D 20704 DESCRIPTION THUMBSCREW STRAIN RELIEF BUSHING LASER SCANNER PRECISION SHAFT Y SWIVEL BLOCK X Y SIDE PLATE X SWIVEL BLOCK Y UP SWIVEL BLOCK Y SWIVEL SHAFT SWIVEL SHAFT LASER SCANNER SPACER X SWIVEL SHAFT GUIDE SHAFT HEIGHT CONTROL BRACKET LASER SCANNER HOUSING WELDED BOX SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 69 SMART FEEDER SERVICE MANUAL ISSUE 12 00 PARTS SECTION I PAGE 70 002K 21390 FIRST PAGE HOLD KIT
115. S The manual is divided by tabs for easy reference To find information listed under section B in the table of contents turn to the tab with the corresponding title Only the major divisions are separated by tabs i e section B is separated from section C with a tab but section B1 is NOT separated from section B2 with a tab In the back of the manual are 5 blank tab cards Label these tabs for the subdivisions you frequently refer to and place them appropriately in the manual 6 INDEX The last section of the manual is an alphabetical index which lists the section and page number for each entry If an entry is more than one word search under the alphabetical listing for the primary or most important word s If the entry is not listed under that word search under the listing of another word in the entry For example you need information regarding Envelope Feeders First look under Feeder If it does not appear there look under Envelope Some entries refer you to other listings For example the entry Insert Feeders may refer you to an entry listed as Feeder Modules These references are indicated by See or See also 420 SERVICE MANUAL ISSUE 09 00 COVER 071 25287 400 E dis 7 LIST OF CHANGES IN THIS REVISION ECN 6874 Date 12 00 Previous release 420 Service Manual Issue D Rev D Changes incorporated in this manual 420 Service Manual Issue 12 00 Rev E gt Section Change I add 002K 08066 B amp H Li
116. SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 49 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 50 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 e Check read probe replace as required e Check pre amp replace as required e 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 operation 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 N 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 e Bad e Bad software Page Out of Seq error Y N Is the problem corrected by any of the followin
117. T FEEDER FOLDER COVER ASSEMBLY 4 002E 19046 CABINET ASSEMBLY 6 0020 08137 CONTROL PANEL ASSEMBLY 9 0020 08135 POWER UNIT A C BOX 11 002E 19047 FEEDER ASSEMBLY page 1 13 002E 19047 FEEDER ASSEMBLY page 2 15 547 25937 500 LEFT SIDE CHASSIS ASSEMBLY 18 547 25938 500 RIGHT SIDE CHASSIS ASSEMBLY 20 0020 16435 SINGULATOR 22 002B 21905 OUTSIDE FEED BELTS 24 0020 08522 FEEDER ELECTRICAL ASSEMBLY 26 0020 17505 CREEPER 28 0020 19017 ACCUMULATOR page 1 30 0020 19017 ACCUMULATOR page 2 32 0020 19017 ACCUMULATOR page 34 0020 08156 KEYBOARD ASSEMNBLY 36 0020 19048 FOLDER ASSEMBLY page 1 38 0020 19048 FOLDER ASSEMBLY page 2 40 0020 19048 FOLDER ASSEMBLY page 42 0020 19048 FOLDER ASSEMBLY page 4
118. T PROCEDURE FOR READ BOARD ERROR READ BOARD REFER TO SECTION F READER SCHEMATIC NOTE If read type is changed in SETUP the Smart Feeder 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 Smart Feeder 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 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 e 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 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 e Bad e 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 SMART FEEDER
119. TALL JAM INTO A document has jammed going into the in ti folder A buckle plate is open The out from folder sensor is out of adjustment The out from folder sensor has failed SPEED IS TOO SLOW Folder speed is below 30 inches per second The folder is jammed The folder speed potentiometer is set too slow The folder speed encoder sensor is out of adjustment or has failed FOLDER IS TOO FAST Folder speed is above 150 inches per second The folder speed potentiometer is set too high The folder speed encoder sensor is out of adjustment or has failed SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 29 SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 30 GBR READER ERRORS s a 77 sequence has changed within a package 1 Misread to group out of sequence 2 Bar code misprinted EXPECTED PAGE ONE First page of package is out of sequence 1 Correct page sequence 2 Check sequence count in read setup Up Down Off GROUP OUT OF RANGE Bad Group the group ID number has changed 1 A page from another group is mixed in with within the same package the same page number 2 Misread PAGE OUT OF RANGE The page numbers within the package are not inji The pages within this group are switched or sequential order missing 2 Misread NV RAM DATA CORRUPT Data in the non volatile ram was changed 1 Power to the CPU 186 was unplugged directly at the board 2 Noise in the 120 VAC PRESETS CORRUPT Prog
120. TED END OF GRP Page out of sequence 1 mark not seen 2 Read error EXPECTED PAGE ONE Page out of sequence Incorrectly printed document Documents out of order 3 Code not seen 4 Check clean and adjust scanner 1 READER ERROR Documents not processing Incorrectly printed document 2 Code not seen 3 Adjust feed sensor NO RESPONSE BLANK PG Scanner did not see bar code Incorrectly printed document Documents out of order 3 Code not seen 4 Check clean and adjust scanner 1 Job setting incorrect 2 Reader error 3 Check clean and adjust scanner GROUP DID NOT CHANGE Expected different group number Incorrectly printed document Documents out of order 3 Code not seen 4 Check clean and adjust scanner 2 Check clean and adjust scanner 2 Code not seen JOB CHANGED IN RUN Job number changed in the bar code 3 Check clean and adjust scanner SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 23 SMART FEEDER SERVICE MANUAL ISSUE 09 00 ACCUMULATOR ERRORS JAM STALL TO RAMPS A document stalled before the stack sensor JAM STALL ON RAMPS A document stalled at the stack sensor The package did not leave the accumulator when the discharge clutch was activated 1 YS EH LE WH PACKAGE DID NOT DUMP PACKAGE NOT REMOVED DUMP BRAKE FAILED FAILED PRESENCE SNS Documents not seen in accumulator Folder and feeder speed are out of adjustment
121. TER DRAWN K CHECKED A Ais mm E sie vom sump Tom s qT CHEN rl SOE v m T sr TITTI ENT YO mmn DET aus IER SENSOR E TEM MODE BLK ET Ein ums E m men m ET rr ur Em ET ETI Dm Dm TES Lor tees ME pu 31 Mim AXI MATERIN INERAL oa ua coc e DRAN LFC 10 93 FINISH CHECKED AS ME APPROVED SCALE yyyyyyyyyyyyyyyyyyyyyyyy
122. YMPTOM Error in folder folder too fast The folder is running at more than 120IPS Probable Cause Solution Solution Check folder encoder replace if necessary Perform opto RCP Folder is running Check the speed controller replace as required Speed potentiometer misadjusted or broken leg on potentiometer Feedback tachometer not working If speed does not decrease by adjusting speed pot then attempt to adjust with MaxSpeed on motor controller board if speed does not adjust defective board If speed oscillates a bad feedback sensor is indicated SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 51 SECTION D REPAIR INFORMATION D 1 INITIAL ACTIONS eese tatus ens 000000000000 2 D la Procedute ti ee PIE 2 D 1b List of Repair Checkout Procedures RCP 3 D 1c Systems Ch c kS ii tero E a S 4 D 2 FEEDER FUNCTION 5 D 2a Description sea reis 5 D 2b Timing Procedures 5 D 2c Feeder Setup and 6 D 3 Repair Checkout Procedures RCP 14 D 4 GBR LINE CODE READ SYSTEMS 27 D 4a Introduction i A petet repete 27 D 4b Setting Up the GBR Line Code 28 D 4c Troubleshooting the GBR Line Code Reader
123. a precise singulating gap These adjustments are Vertical Position of Singulating Roller Singulating Roller parallel with lower rollers 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 7 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 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 4 Attempt to pull the document out while slowly raising the Singulating Roller with the chrome knurled knob 5 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 SMART FEEDER SERVICE MANUAL paper ISSUE 09 00 REPAIR INFORMATION
124. a document stalled or 1 A document has jammed under or into jammed under or into the transfer conveyor jam transfer conveyor sensor sensor 2 A document has stalled under the into transfer conveyor sensor 3 The into transfer conveyor sensor is out of adjustment or has failed SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 39 SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 40 SYSTEM ERRORS NV RAM DATA CORRUPT Data in the non volatile ram was changed 1 Power to the CPU 186 was unplugged directly at the board 2 Noise in the 120 VAC power 3 Battery jumper removed from CPU 186 NOT ENOUGH NV RAM Battery back up on the non volatile ram chip is 1 Ram needs to be replaced bad PRESETS CORRUPT Program error internal processing error number 1 Should not occur If error is displayed cycle one 1 the main power switch off on 2 If the problem persists contact the technical support center E STOP INTERLOCK Emergency interlock circuit is open 1 The emergency stop switch was pressed while running 2 An interlock is open check that all covers are closed 3 The 24V power supply is unplugged NO USE TIMEOUT No use shutdown automatic shut down of the 1 No documents have been fed during the system after a period user selected of inactivity preset time out set in maintenance mode 2 10 minutes NO CONV CONNECTED Looking for Transfer conveyor 1 Transfer co
125. a good interface to the Inserting machine 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 INSTALLATION SECTION PAGE 7 SMART FEEDER SERVICE MANUAL ISSUE 09 00 INSTALLATION SECTION G PAGE 8 Move Closer To Increase Duration To PF300 Folder Loosen Set E Screws To Rotate wd Magnets Slide To Change gt Duration Magnetic M t Block i agnet Block A ne Rotate For Switch Enlarged Proper Timing at Left Xz1 Pack Length O Point at which gripper arm takes pack 2 Demand switch turns ON 8 Demand switch turns OFF Demand Switch Adjustment Fig G 7 SECTION H MISCELLANEOUS H 1 Service Bulletins n a H 2 Purchased Components Manuals Model 30 Hardware Operations Manual The Accu Sort Model 30 Scanner is used to read bar code SmartFeeder 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 SMART FEEDER SERVICE MANUAL ISSUE 09 00 MISCELLANEOUS SECTION H PAGE 1 SMART FEEDER SERVICE MANUAL ISSUE 09 00 MISCELLANEOUS SECTION H PAGE2 NOTES SECTION I PARTS 0010 19045 SMART FEEDER FOLDER TOP ASSEMBLY 2 0010 19045 SMAR
126. 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 Any time a new CPU 186 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 15 different from the expected stored result See above SMART FEEDER SERVICE MANUAL ISSUE 09 00 C 3c Specific Errors Causes and Solutions Refer to the tables on the following pages to identify likely causes and the possible solutions to errors PROBLEM ANALYSIS SECTION C PAGE 19 SMART FEEDER SERVICE MANUAL ISSUE 09 00 BAR CODE READER ERRORS Answer not received document in accumulator 1 NO RESPONSE TIMEOUT INVALID
127. ad SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 57 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 58 PRESETS CORRUPT Some of the preset parameters have fallen out of their defined maximum or minimum range ERROR SUGGESTION 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 186 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 186 board is probably bad INVALID CUST ID A page within a set has a customer id that does not match the other pages in the set ERROR SUGGESTION If the customer id did not change within the set check to see that the proper barcode is printed on the page and that the barcode matches the specifications GROUP SEQUENCE ERROR The page that was just fed did not follow the selected group sequencing pattern ERROR SUGGESTION 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 GROUP CHANGED IN SET Every page within a set is supposed to have the same group number and the page that was just fed did not ERROR SUGGESTION If the group did not change within the set check to see that the proper barcode is print
128. al Message output Pinnacle new plus Group number on end OQ Q N O 18 18 FEED BRAKE ENABLE DISABLE FEED BRAKE is normally set to DISABLE This setup option allows ENABLING or DISABLING the energizing of a feeder brake when the Feed Clutch is de energized Should the paper in the feeder section begin to prematurely exit under the pinch roller due to higher operation speeds and block the feed sensor then the FEED BRAKE can be enabled to retard the paper feed This feed brake is only available on the Model 438 and the enable or disable will not affect earlier production machines C 2e CYCLE TEST MENU C 2 INSERTER TEST MENU SELECT TEST ENTER ver 07625 024 This is only available if the CONFIG ID SETUP Section C2 d INPUT OUTPUT SPEED SETUP CYCLE INSERTER is set to CONVEYOR W INSERTER SELECT CYCLE TEST UNDO EXIT SELECT TEST ENTER ver 07625 024 INPUT OUTPUT SPEED SETUP CYCLE INSERTER After pressing the TEST key the SELECT TEST message appears asking which test to perform INSERTER SETUP UNDO EXIT ENCODER TEST TIMING Press the or key to scroll through the available choices until CYCLE is highlighted INSERTER ENCODER POSITION UNDO DEGREES 000 HOME 0 Press ENTER to select 1 CYCLE ACCUMULATOR CLUTCH BRAKE CYCLING ACCUMULATOR UNDO EXIT SIMULATING 10 000 PACKAGES PER HOUR 2 CYCLE FEEDER CLUTCH CYCLING FEEDER UNDO EXIT SIMULATING 10 000 P
129. and Plate 3 1 3 Plates 1 and 4 are deflected 6 Slide the Fold Stop so its front edge lines up with the appropriate setting on the Left and Right Fold Plate Scales for fold plate 3 7 Tighten the Fold Stop thumb wheel SMART FEEDER SERVICE MANUAL ISSUE 09 00 Fold Charts F en m NOTE Fold plate 3 will always be used Modify fold plate 3 to perform either the second or final document fold Always use fold plate 3 for the second or final fold 8 If necessary adjust the Fold Stop Level thumb wheel until the measurement on each of the fold plate scales is exactly the same NAME AT THE BOTTOM NAME AT THE TOP ACCORDIAN FOLD D QUARTER FOLD C ACCORDIAN FOLD D QUARTER FOLD ead form face down Bottom edge leading Z to A roallalion User Plate 41 113 and Plate 2 1 3 3 and 4 aro deflected Food form lace denen leading Z 16 A Ven Plate 2 1 3 and Plato 3 1 31 Ptatns 1 and 74 ard dellacled eed farm taco down Bottom edge leading 7 10 A Use Cale 1 41 2 f and Plate 3 114 ka 2 ari 4 ara dellected ne form t ce down Bolom ado leading 7 16 comal Use 20046 1 1 2 and Plate 3 1 4 2 and are dellacted 9 Insert the open end of fold plate 43 back into the folder making sure that the fold plate rests on the fold plate stops REPAIR INFORMATION SECTION D P
130. ards and board components are well seated Restart machine Swap boards with known good ones NV RAM DATA CORRUPT Data in the non volatile ram was changed Power to the CPU 186 was unplugged directly at the board Noise in the 120 VAC power NOT ENOUGH NV RAM Battery back up on the CPU 186 is bad Board needs to be replaced PRESETS CORRUPT Rn error internal processing error number 1 Should not occur If error is displayed cycle one 7 main power switch off on DUAL PORT RAM FAILED E failure on reader board Battery failed or battery jumper missing BAD ON CHIP 8051 RAM gt Bad CPU 186 board INVALID COMMAND INVALID PIC INT INVALID SETUP DATA Reader board memory corrupted 1 Restart machine PARITY ERROR 1 Actual lines of codes must match parity setting odd or even 2 Bad code UNEXPECTED RESPONSE 1 Paperjam SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 35 SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 36 Lees ES 3 Reader encoder bad EXPECTED READING Blank page Read encoder failed paper jam Feed sensor out of adjustment READER REBOOTED Reader encoder failed Bad read board INVALID READER ERROR CPU 186 does not understand reader INVALID CAL SETUP Feed through calibration sheet several times to ensure that encoder is reading consistent read numbers Reader encoder bad YES NO EOG ARE SAME European Mismatched group marks cause stall and EOG ma
131. can head at a five to ten degree angle so the laser beam reaches the bar code at a slight angle SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 55 SMART FEEDER SERVICE MANUAL D 5d Setting 420 to Read 3 of 9 Laser Bar Code Select READ on the Smart Feeder display screen Select READ TYPE Press ENTER Select BAR Press ENTER This will return you to the read type screen at this point press EXIT Switch the Smart Feeder main power OFF and then back ON to set the newly selected read type in the Smart Feeder s memory Select READ again Select TEST press ENTER Select CONTINUOUS BAR READ press ENTER 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 Press EXIT Select READ again Select SETUP press ENTER ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 56 Select SELECT BAR JOB press ENTER Select the Job Number for you code by using the or keys This number is provided to you by GBR at the time of sale or installation if you are unsure of this number please give the GBR Sales Department a call Press ENTER and then press EXIT to get out of the main menu D 5e Adjusting the Paper Guides In order for your laser scanner to read the bar code there can be nothing blocking its path The Paper Guides provi
132. d to the Smart Feeder Y N Perform the Paper Jam in Feeder RCP With the Smart Feeder 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 D 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 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
133. de set includes 0 9 A Z which is used for the start and stop characters and six other symbols and 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 D 5c Adjusting the 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 travel 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 s
134. ded with the 3 of 9 Laser Option are custom adjustable for your specific code location Place these guides to provide as much support evenly across the paper path as possible without interfering with the lasers path D 5f Laser Bar Code Read Errors NO RESPONSE TIMEOUT The reader did not respond with a reading in the proper amount of time ERROR SUGGESTION Make sure that the barcode reader is aligned with the code properly Make sure that the machine power was cycled after the read type had been set to BAR INVALID COMMAND The software was asked to do something that it does not know how to do ERROR SUGGESTION You should never get this error If you do get this error either the software is bad or the 186 cpu board is bad BAD READ The barcode reader returned an error code ERROR SUGGESTION Make sure that the barcode reader is lined up with the code Make sure that the barcode print on the paper is good quality PAGE OUT OF SEQUENCE The page that was just fed did not follow the selected page sequencing pattern ERROR SUGGESTION 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 NOT ENOUGH NV RAM The program has run out of non volatile ram ERROR SUGGESTION You should never get this error If you do get this error either the software is bad or the 186 cpu board is b
135. dge of the document The second Line Code mark needs to be precisely placed ISSUE 09 00 SMART FEEDER SERVICE MANUAL 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 of the expected number of encoder signals it is considered a valid calibration value 0 442 Calibration Procedure FOR 1 8 AND 1 6 SPACED LINE CODES 1 Check all mechanical setups in the machine Examples Friction feeder is free of mechanical binding Singulator is adjusted properly Documents are processed through machine without distorting the paper All paper hold downs are set up properly Paper rails are set to the proper width 2 On the operator s configuration keyboard 22 keys directly under display select OMR reading enabled 3 On the operator s configuration keyboard select the proper line code spacing you desire to calibrate 1 6 or 1 8 4 On the operator s configuration keyboard select RECALIBRATE 5 Now feed a single Calibration document on the machine REPAIR INFORMATION SECTION D PAGE 37 SMART FEEDER SERVICE MANUAL 6 If none of the following errors are d
136. dible 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 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 e Check the power supply PS1 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 21 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 22 REPAIR CHECKOUT PROCEDURE FOR SMALL SHEET Clear the paper that was jammed in the machine and remove any obstructions Does the paper move through the feeder properly Y N Check that the paper size setup is correct e 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 Remove the covers from the feeder Does the feed motor turn on Y N 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 e Replace 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
137. e COOOOH to FFFFFH STD Bus Memory Byte access only 16 and 20 bit addressing Up to 1 M byte Minimum access time of 207 ns at 8 MHz with no wait states Address Range 40000H to BFFFFH with up to 256k bytes of on board RAM 80000H to BFFFFH with 512k byte on board RAM option STD Bus I O ISSUE 09 99 Byte access only Minimum access time of 207 ns at 8 MHz with no wait states Address range from 0 to 7FFFH with no programmed wait states Address range from 8000H to 80FFH with three programmed wait states PRINTED WIRING BOARDS SECTION E PAGE 5 SMART FEEDER SERVICE MANUAL ISSUE 09 99 PRINTED WIRING BOARDS SECTION E PAGE 6 SBX Interface Real Time Clock RTC72421 e Byte access only e Binary coded decimal format e Two module selects e Seconds minutes hours day of month month e One DMA acknowledge select year and day of week Serial I O two DUART s Electrical Requirements e 5 at 500 mA 12 Vdc at 30 mA e Two dedicated RS 232 serial ports e Two configurable RS 232 RS 485 RS 422 serial ports e 12Vdc at 30 rnA e Asynchronous data rates from 50 baud to 38 400 e Operating temperature range from 0 C to 55 C baud Programmable I O 8255 e 24 parallel I O lines e Default to input mode e Interface direct to Opto 22 rack with 50 pin connector E 3c Functional description Using the Connectors connectors are used for serial communication the STD Bus peripherals an inter
138. e GBR Line Code Reader 1 Turn on the Smart Feeder press the READ button and go into READ TYPE 2 Make sure that GBR LINE is selected 3 Go into the ON OFF menu and set it to ON 4 Exit out of the READ screens and cycle the power to the Smart Feeder turn the Smart Feeder main power switch off and on 5 Press the READ button and go into SETUP gt READER SETUP gt WHT LVL 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 ENTER GAIN OFFSET 2 and LAMP will set automatically The system will beep to indicate that it is done c Check that e OFFSET 2 is between 100 and 150 e LAMP is between 150 and 240 d Exit out of this screen and go to the next step NOTE If you do not get values within these ranges check to see that the read probe is 1 2 to 5 8 inch away from the paper and make sure that the light beam is on a white portion of the paper Furthermore the wrong probe could be selected See Troubleshooting the GBR Line Code Reader step 3 in this section for directions on selecting probes SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 31 SMART FEEDER SERVICE MANUAL 6 Go to BLK LVL and press ENTER a b Hand feed a piece of the stock until the light beam is on one of the line code marks voltage should drop to 0 volts While you are hand feeding thi
139. e necessary plates 30 Check to see that the Fold Stop measurement is the same on both scales Adjust the Fold Stop Level Thumb screw if necessary THE FOLDER SET UP IS NOW COMPLETE D 7f Timing Procedures not applicable REPAIR INFORMATION SECTION D PAGE 73 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 74 D 7g Folder Infeed Roller Tension Adjustment There is a tension adjustment between rollers 1 and 2 only This adjustment is found on each end of the rollers To bring rollers closer together loosen locking bolt and Centers slide tension adjuster in direction 1 LoosenScrew To widen gap between roller push adjuster in direction to Adjust 2 Ensure that the spacing between rollers is equal on both sides This may be accomplished by feeding a strip of paper between the rollers and checking for equal drag at both sides Feed a strip of paper approx 2 in wide into the infeed Pull Paper Strips Through rollers using the hand knob on the side of the folder Rollers By Hand Tension Adjuster Figure Hold the hand knob still and slowly pull the paper strip from the rollers Repeat on other side of roller There should be an equal amount of drag on each side Slide Guide to Adjust D 7h Removal and Replacement of Folder Components NOTE The folder portion of the Smart Feeder is extensively modified from the original equipment DO NOT use the MB 354 Folder
140. e removed in order to clean all fold rollers For SMART FEEDER SERVICE MANUAL ISSUE 09 00 PREVENTIVE MAINTENANCE SECTION B PAGE 1 SMART FEEDER SERVICE MANUAL more information on cleaning the fold rollers refer to your 420 Operator Manual B 2a3 Machine Cabinets and Covers Clean the machine cabinets and covers using a soft damp cloth B 2a4 Paper Hopper The feed belt should be cleaned with a substance such as isopropyl alcohol that does not leave a film Apply some alcohol to a rag then lightly rub all dirt and film off of the belts B 2a5 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 NOTE If there is no rounded spot available the singulator needs to be replaced immediately Once this is accomplished raise the singulator roller ap proximately 3 4 from present setting Pass an alcohol dampened rag under the bottom of the singulator roller Be sure ISSUE 09 00 PREVENTIVE MAINTENANCE SECTION B PAGE 2 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 420 NOTE If a mechanical c
141. e right of station 1 at table height 2 Jog inserter so gripper arms are moving towards insert stations stop when vertical Gripper Arms Orientation to 420 Figure G 3 3 SMART FEEDER SERVICE MANUAL 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 universal bracket on outer frame cover or deck dr Switch Block and Bracket Figure G 4 Install double magnet block on large shaft NOTE Do not tighten yet snug one screw Turn on the 420 press the following keys on the operator keypad TEST gt gt ENTER ENTER ISSUE 09 00 Magnetic Block Figure G5 You are now in the input test section Connect demand switch to the provided cable from the 420 output conveyor Jog inserter to rotate magnet block assembly Desired timing is when the demand input 420 display goes on when the grip arm is one insert from output conveyor while moving away adjust position of magnet block to accomplish this When satisfied with the timing tighten all set screws INSTALLATION SECTION G PAGE 5 SMART FEEDER SERVICE MANUAL G 5 TRANSFER CONVEYOR ADJUSTMENTS G 5a 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 Positioni
142. eclared 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 e NO GATE MARK DETECTED e NO GATE MARK DETECTED IN 2ND BANK e CALIBRATION OUT OF RANGE 7 If a bad calibration is indicated RECALIBRATE must again be selected before another Calibration document is fed Go back to step 4 D 4e Computer Preset Line Read Page Set Up The reader must be taught the exact presets of the type of code you wish to read First make sure LINE READ has been selected Enter the READ mode and scroll to READ TYPE press ENTER Next scroll to GBR LINE READ and press ENTER Enter the READ mode and scroll to SETUP press ENTER and scroll to PAGE SETUP press ENTER There are numerous different presets and each one has several levels of screens Each of these presets must be set or turned off for proper reading In some cases entering a preset will exit you out of read set up and it will be necessary to re enter and scroll to the next pre set ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 38 Smart Feeder Reader Screens READ TYPE TEST Reader Setu ON OFF SETUP Page Setup 1 17 DEMAND FEED DEMAND FEED FIELD gt UNDO ENTER DEMAND FEED NORMAL REVERSE YES NO LAST PAGE Use the cursor keys lt gt until the desired choice flashes Press ENTER NORMAL The machine will demand feed on the abs
143. ed on the page and that the barcode matches the specifications Check to see that the proper barcode job is selected ROLL 7 OUT OF SEQ The page that was just fed did not follow the selected roll sequencing pattern ERROR SUGGESTION the roll 7 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 EXPECTED END OF GRP If 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 ERROR SUGGESTION 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 EXPECTED PAGE ONE If page sequencing up the software expects the first page of each set to be either a0 or 1 depending on what minimum page number was selected in the page setup ERROR SUGGESTION 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 READER ERROR An undefined error was flagged by the program ERROR SUGGESTION This error sho
144. en to SSR4 when rack 1 opto 2 LED is lit in the Smart Feeder Is there voltage at the connector that feeds the motor when the RESET ON key is pressed Y N Check fuse F2 Is it good e Replace 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 e Check relay SSR1 e Make sure the speed pot is properly set Check for 120VAC across the line side of LF4 Check for 90VDC across the and terminals of the creeper motor Are these voltages present Y N e Replace LF4 e Replace the creeper motor Paper is fed through the Feeder as the Feed Clutch fires 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 input opto 0 2 opto module 2 on opto rack 0 Does LED light when encoder operates Y N 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 Y Y Y Check the pico fuse of the opto module Replace if required does this correct problem Y N Check the encoder Replace encoder N Check a different input to ensure the audible signal on the display is working e Fix or replace display board N Check connections between opto rack and CPU
145. ence 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 the 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 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 2 17 SEQUENCE PAGE SEQUENCE lt gt UNDO ENTER UP DOWN ITEM COUNT ROLL DWN ROLL UP OFF Use the cursor keys until the desired choice flashes Press ENTER UP Choose if the page is counted UP 1 2 3 4 DOWN Choose if the page is counted DOWN 4 3 2 1 ITEM COUNT Choose when the first sheet in a package indicates the total number of sheets in that package ROLL DOWN Cycle counts down sequentially from a selectable value ROLL UP Cycle counts up sequentially to a selectable value OFF If there is no page sequence enter OFF 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
146. enu from the VIP display Select INPUT from the submenu and select Transfer Conv IN Sens input As the package enters the transfer conveyor the audible beep should be heard Observe opto 0 12 opto module 12 on opto rack 0 Does the red LED illuminate each time the sensor is blocked and go out when the sensor is unblocked Y N Check a different input to ensure the audible signal on the display is working e Replace display board Does the sensor state change as indicated by red LED off green LED on when sensor is covered Y N Check the 24V supply to sensor Is the sensor powered Y N Check the following is the problem corrected Alignment of prism Gain adjustment on sensor Damaged fibers Replace the opto module Does the opto module work as indicated by LED on off as sensor state changes Y N Check the wiring between the transfer conveyor infeed 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 Check wiring to CPU Troubleshoot or replace CPU 186 if necessary Y D 9 POWER UNIT REFER TO SECTION F POWER UNIT SCHEMATIC The Power Unit is located inside the cabinet and consists of the following components 1 Master Relay Electric safety interlock switch 4 5 VDC Power Supply PS1 2 Fuses Fuse tips illuminate when the fuse is bad
147. er 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 otion 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 Soe Chon If 24VDC is not replace the clutch v SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 25 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 26 REPAIR CHECKOUT PROCEDURE FOR TWO SHEET SENSOR 2 SHEET SENSOR REFER TO SECTION F 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 the sensor is unblocked N Check a different input to ensure the audible signal on the display is working N Is the green LED ON Y N Adjust the sensor N Make sure sensor amplifier is set for Dark ON correct if necessary e 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 sens
148. erfere with the icd PESE watch dog timer refresh which could result in a hardware 809 SER 22 reset of the CPU 186 Most STD Bus peripherals do not AD5 RESERVED 24 NC use BUSRQ ADA TDMA 26 NC DMA channel 1 is interfaced to the STD Bus CNTRL AD3 27 MD3 OPT1 28 A peripheral setting CNTRL low will enable the DMA ADO OPTO 50 NE request input to DMA channel 1 SBX Interface J2 A The Small Bus eXpansion concept was developed by Intel for ADO 33 MDRQT 34 DRQO use with its Multi Bus boards This concept allows inexpensive GND 5 36 5 O modules to be added to the processor board The SBX SBX INTERFACE CONNECTIONS RS 232 Serial Interface J3 J4 J5 and J6 Up to four active RS 232 channels can be used on the CPU 186 Each channel has its own 14 pin Connector which can be connected to a DB 25 connector with a 14 pin ribbon cable to provide Communication with most DTE RS 232 devices DB 25 RS 232 CPU 186 CPU 186 PINS SIGNAL SIGNAL J3 J4 J5 OR J6 PINS 1 CHASSIS GND GROUND TXD RXD TXD RXD CTS RTS SIGNAL GND GROUND DIR CTS J3 J4 J5 AND J6 RS 232 Serial Interface Connectors Figure E 3 See the Figure E 2 for the physical placement of the RS 232 connectors RS 485 RS 422 Serial Interface J7 and J8 The RS 485 RS 422 interface connectors are J7 and J8 The cabling for J7 and J8is illustrated in the figure below
149. face to SBX daughter boards four timer counters and 24 parallel lines CPU 186 I O CONNECTORS J1 STD BUS EDGE CONNECTOR J2 SBX CONNECTOR J3 RS 232 COM1 J4 RS 232 COM2 J5 RS 232 COM3 J6 RS 232 COM4 J7 RS 85 COM3 OR RS 422 COM3 TxD J8 RS 485 COM4 OR RS 422 COM3 RxD J9 COUNTER TIMER INTERFACE J10 24 PROGRAMMABLE I O LINES Serial channels COM3 and COM4 can be configured for either RS 232 or RS 485 RS 422 but not both If COM3 is configured for RS 232 then a cable connection is made to J5 If COM3 is configured for RS 485 then a cable connection is made to J7 If is configured for RS 422 then a cable connection is made to both J7 SMART FEEDER SERVICE MANUAL ISSUE 09 99 TxD and J8 RxD and 4 must then be configured for RS 232 Refer to the CPU 186 component layout in paragraph E3 a for connector locations The STD Bus manufacturers group has developed a standard definition of the STD Bus connections and timing for the 8088 family of microprocessors The CPU 186 follows this standard closely except for two deviations One is that address lines AS through A10 are not tri stated during interrupt acknowledge cycles The other is that MCSYNC is not tri stated during a BUSRQ period Neither of these deviations will cause problems for those using general STD Bus peripherals The CPU 186 cannot execute programs or attempt word accesses of the STD Bus The STD Bus is an 8 bit bus end currently there is
150. g Edge 1 3 1 3 x 1 3 1 3 a X Address trailing and 1 2 c L x 1 3 1 3 down 1 3 1 3 X Setting Folds Figure D 7d Features of the Fold Plates DEFLECTOR The operator should become familiar with the parts and Remove and reverse the fold plate to act as a deflector features of the folder when a fold plate is not required for the selected fold FOLD STOP Fold Stop Fine Adjustment The fold stop is an adjustable bar that regulates the fold Thumb Wheel height for a particular fold plate SCALE Fold Stop Level Use the scales at each fold plate to set the proper fold Thumb Wheel depth for that fold plate Fold Stop Thumb Wheel FOLD STOP THUMBSCREW Loosen the thumbscrew to adjust the fold stop to the proper fold depth Tightening the fold stop thumbscrew locks the fold stop into position FOLD STOP FINE ADJUSTMENT THUMBSCREW To obtain a more precise and even fold of the material use the fine adjustment thumbscrew Fold Plate Features Figure SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 69 SMART FEEDER SERVICE MANUAL FOLD PLATE DEFLECTOR ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 70 FOLD PLATE ACTIVATOR mad FOLD PLATE NOTCHES Side View of Folder Plates Figure D 7e Setup and Adjustments 1 Determine the type of fold required for the job 2 Refer t
151. g 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 UARTs e Bad software Invalid Group error Y N 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 e Bad e Bad software SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 51 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 52 Expected Page One error Y N 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 e Bad UARTSs e Bad software Group Out of Range error Y Is the group code in the range 0 7 e Check that code is OK Page Out of Range error similar to Group Out of Range error page range must be within 1 7 Presets Corrupt error a CPU 186 error that would likely occur on power up Yes EOG Are Same error this error is only associated with European machines Y N Is the problem corrected by any of the following tests e Check read setup again particularly focu
152. hen 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 INTRODUCTION SECTION A PAGE 3 ISSUE 09 00 SMART FEEDER SERVICE MANUAL 071 25287 400 SMART FEEDER SERVICE MANUAL ISSUE 09 00 INTRODUCTION 071 25287 400 SECTION A PAGE 4 SMART FEEDER and Bell amp Howell Inserter Figure A 1 Feeder Accumulator Displav Transfer Folder Creeper Convevor Optional Barcode Reader Cabinet with Flartranirs Layout of Smart Feeder Figure A 2 SMART FEEDER SERVICE MANUAL ISSUE 09 00 INTRODUCTION
153. if the lower line is set to zero even if there is a line in the code for that station 9 ON indicates an insert will be pulled from a station whether or not ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 2 there is a line in the line code for that station if the lower line is set to 9 DIVERT BATCH SHEET SHEET BATCH COUNT lt gt UNDO ENTER BATCH PKG PACK BATCH COUNT lt gt UNDO ENTER if installed To access particular options scroll through menu choices using the keys on the key pad When the desired option is flashing press the Enter key to select that choice 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 EXIT lt gt ites fenter SHEET SIZE 1 2 3 7 BATCH BATCH SMART FEEDER DISPLAY FIGURE C 1 C 2a INPUT TEST MENU SELECT TEST ENTER ver 07625 xxx INPUT OUTPUT SPEED SETUP CYCLE INSERTER if installed SELECT INPUT lt MORE Rack Opto Feed Sensor 0 0 1 2 2 sheet Sensor 0 16 3 Feeder Speed Encoder 0 2 1 10 Inserter Deg Encoder 0 5 11 Inserter Home Encoder 0 14 7 i 0 1 Interlock 0 11 18 Conv Option Line 0 0 6 0 7 19 Conv Option Line 1 20 Conv Option Line 2 0 15 SMART FEEDER SERVICE MANUAL ISSUE 09 00 After pressing the TEST key this message appears
154. in SETUP Check adjustment of feed sensor adjust if necessary Check Input Test 5 19 LED on opto 0 1 should change Perform Feed Sensor RCP C 4c SYMPTOM Error in feeder long sheet A document entered the folder and did not exit or was not seen exiting Solution Paper did not reach accumulator Check that sheet length is properly set in SETUP Set correct sheet length and run another sheet Check adjustment of stack sensor adjust if necessary Perform Stack Sensor RCP Stack sensor C 4d SYMPTOM Error in feeder two sheets A document entered the folder and did not exit or was not seen exiting Solution Valid error adjust singulator for correct stock Double detect sensor Check adjustment of double detect sensor adjust if necessary with two sheets red LED should not be lit Check Input Test 2 19 LED on opto 0 16 should change Perform Sensor RCP READ ERRORS C 4e SYMPTOM Error in read no response timeout GBR OMR code not being read Probable Cause Solution Code was not seen after leading edge tripped sensor Check that code is printed on page Check wiring to CPU Perform No Response RCP C 4f SYMPTOM Error in read code misread GBR OMR code not read correctly Probable Cause Solution Code was not interpreted correctly Check for paper flutter under read head Check for pullout roller slipping Perform read setup to ensure voltages are correct Perform Reader Board RCP Chec
155. 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 420 SERVICE MANUAL ISSUE 12 00 COVER 071 25287 400 E 2 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 A1 a is a subdivision of A1 Section A1 a1 is a subsection of A1 a 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 A detailed table of contents is located on the first page of each section SECTION A INTRODUCTION Machine Orientation Machine Specifications SECTION B PREVENTATIVE MAINTENANCE SECTION C PROBLEM ANALYSIS Input and Output Te
156. it sensor 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 420 G 5f Testing of the exit sensor The Exit sensor on a 420 creates an interrupt to the control card This interrupt is what permits accurate position of packages on the Transfer conveyor Testing that the interrupt is seen 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 420 and command the machine to Dump SMART FEEDER SERVICE MANUAL ISSUE 09 00 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 186 at header J9 The signal comes from J10 a 50 pin in line ribbon cable header G 6 SETUP OF DEMAND SWITCH Demand switch on off timing is critical The setup of this timing permits the 420 to achieve
157. k UARTs on CPU replace as necessary Replace software SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 43 SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 44 C 4g SYMPTOM Error in read group out of seq Package sequence has been corrupted Probable Solution l Group sequence is not correct did not increment or decrement Inspect stock for packs out of sequence properly Check sequence count in read setup Up Down Off Check setup voltages to ensure dots are not being seen as lines verify by running stock with scope connected to read board C 4h SYMPTOM Error in read expected end of group Package sequence has been corrupted ______________ Solution SS Group number changed without reader seeing EOG Verify that code is not misprinted Perform read setup to ensure proper EOG parameter Observe waveform with scope connected to read board SYMPTOM Error in read blank page Page has no code printed Probable Cause Po Solution No code was seen Verify feed sensor is functioning properly check gain Perform blank page RCP Perform read setup to ensure voltages are correct Perform reader board RCP Check UARTs on CPU replace as necessary Replace software C 4j SYMPTOM Error in read short group EOG read before expected Probable Cause Solution Group number changed before page one or
158. kage Perform accumulator sensor input RCP if Package Not Removed is displayed CPU reset C 4w SYMPTOM Error in accumulator dump brake fail Paper not exiting accumulator Solution Package stopped in accumulator improperly positioned Check position and adjustment of stack sensor adjust if necessary Check dump clutch brake Perform stack sensor input RCP Perform dump clutch output RCP C 4x SYMPTOM Error accumulator in vs out speed Speed disparity in accumulator only applies to special sofware SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 49 SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 50 C 4y SYMPTOM Error in folder Doc jammed inside A document entered the folder and did not exit or was not seen exiting Solution A mechanical fault has caused the paper to crash Make sure the buckle plates are seated correctly and are adjusted properly Observe if paper is hitting the buckle infeeds adjust to correct Check if the rollers are damaged replace as necessary Check if the infeed or outfeed guides are damaged replace as necessar The transfer conveyor infeed sensor is not seeing the paper Perform transfer conveyor infeed sensor RCP Perform Opto RCP C 4z SYMPTOM Error in folder Speed is too low The folder is running at less than 30IPS or not running at all Probable Cause Folder is running Folder is not running C 4aa S
159. lative 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 C 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 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 7 SMART FEEDER SERVICE MANUAL D 2c3 Paper Level Detector The demand switch monitors the paper through a metal wand On the top of the wand is a spring loaded hex head adjustment bolt which when turned raises and lowers the wand e Raise the wand to allow more paper to be fed into the feeder Lower the wand to reduce the amount of paper SINGULA 2 ADJUSTMENT mas en Ne N l E E E m Al Sms La ter O Sal di Singulator and Paper Demand Figure ISSUE 09 00 R
160. lator in vs out speed SYMPTOM Error in folder Doc jammed inside SYMPTOM Error in folder Speed is too low SYMPTOM Error in folder folder too fast PROBLEM ANALYSIS SECTION C PAGE 1 SMART FEEDER SERVICE MANUAL C 1 MACHINE DIAGNOSTICS Diagnostics on the SMART FEEDER is performed through the display panel and related software Refer to section C2 2 SCREEN OPERATION There are several screens available through the display These screens provide set up monitoring and alteration capabilities for the SMART FEEDER They are illustrated in the charts which follow READ Refer to Section D for screen directions ON OFF SETUP READ TYPE TEST TEST INPUT OUTPUT SPEED SETUP CYCLE INSERTER JOB GET JOB SAVE JOB SHEET LENGTH 5 5 7 in 8 5 in 11in 14 in A4 5 SIZE 1234567 VARIABLE INSERT E 0 9 ON SELECT STATION 8 0 7 0 6 6 5 5 4 4 3 3 2 2 1 1 The SELECT settings on the lower line determine which inserts will be pulled when there is a line present in the line code for that position For instance when using GBR Line Code if there is a line present in the line code for the 4 station and this screen has been set for 4 4 an insert will be pulled from station 4 If the screen had been set to 3 4 an insert would be pulled from station 3 On the upper line 0 OFF indicates no inserts will be pulled
161. ment 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 2 Buffered transfer conveyor where nest folded document s are placed in an open inserter feed gripper arm station 4 Transfer conveyor where the nest folded document s are presented to the gripper arm SMART FEEDER SERVICE MANUAL ISSUE 09 00 D 7b 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 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 REPAIR INFORMATION SECTION D PAGE 65 SMART FEEDER SERVICE MANUAL ISSUE 09 00 D 7c Components of the Fold Unit D 7c1 FOLD ROLLERS The fold rollers move the document through the fold
162. n 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 Go into SETUP gt READER SETUP gt CUSTOM SETUP and set the LAMP value to 255 Look at the lamp on the other probe or where the other probe ISSUE 09 00 would have been connected 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 gt PAGE SETUP gt PROBE A OR B and select the other probe Exit all the way out of the setup screens and cycle the power on the Smart Feeder After cycling the power to the Smart Feeder go into SETUP gt READER SETUP and setup the reader see SETTING UP THE GBR LINE CODE READER REPAIR INFORMATION SECTION D PAGE 35 SMART FEEDER SERVICE MANUAL ISSUE 09 00 Miscellaneous Problems TRIP POINT 1 1 If EPROMS are swapped out on the CPU 186 board and the VIP display is TRIP POINT 2 locked up with the message reader errored when the Smart Feeder is powered do the following e Turn the Smart Feeder off and hand feed a sheet of paper into the accumulator e Turn the Smart Feeder on the error Package Not Removed will be displayed on the screen and go into READ gt SETUP gt PAGE SETUP and setup your page as you would normally e Cycle
163. n step 3 e 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 32 from the paper 2 If frequent misreads are occurring and the probe lamp is bright do the following into READ gt SETUP gt PAGE SETUP and make sure that all of your page settings are properly configured into READ TEST gt THIS READING and compare the marks on the page in question to the 1 s 0 on the screen e f more 15 appear on the screen than lines on the page go into SETUP gt READER SETUP gt CUSTOM SETUP and increase OFFSET 2 by 1 ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 34 volts 1 increment Repeat this step until the misreads go away If more 05 appear on the screen than lines on the page go into SETUP gt READER SETUP CUSTOM SETUP and decrease OFFSET 2 by 1 volts 1 decrement Repeat this step until the misreads go away If the correct number of 1 s 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 back into PAGE SETUP 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 So if you have a
164. nd switch must be added to the Inserter G 5E CONFIGURATION OF EXIT SENSOR MODULE cte 7 G 5F TESTING OF THE EXIT 5 5 00070772 7 These changes may be done once and left that way so the G 6 SETUP OF DEMAND SWITCHA 7 420 may be used again without going through them each time If this is done however this station will not be usable in normal operation SMART FEEDER SERVICE MANUAL ISSUE 09 00 INSTALLATION SECTION PAGE 1 SMART FEEDER SERVICE MANUAL ISSUE 09 00 INSTALLATION SECTION PAGE 2 G 1 REMOVAL OF HOPPER SIDE PLATES Left Side Right Sid NOTE View of Fig G 1 is from 420 side of inserter Guide Plate ight Side Guide Plate 1 Remove four screws holding side plate adjustment shaft blocks Remove 4 Screws 2 Remove shaft E clips 4 3 Unlock right side plate and slide off end of shaft 4 Slide left side plate out to end of shah 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 Snap Rings the inserter 2 gt G 2 REMOVE HOPPER GUIDE DA 6 OS Remove cover directly behind insert station 2 Unlock mount remove outer snap rings L 255 GN 3 Slide shaft to right the left side mounting bracket will drop gt x down under the inserter deck SS Suction Cup 4 Slide shaft to left the
165. ne 0 At Line 0 Repeat Every 0 Job 41 Yes PROBLEM ANALYSIS SECTION C PAGE 16 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 e Select Postal Meter Divert Enable ON to operate 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 ON in degrees 0 to 350 e Enter Meter OFF in degrees 0 to 350 e Enter Meter Position STA 1 to 12 after envelope insert station Postal Meter 2 e Enter Meter ON in degrees 0 to 350 e Enter Meter OFF in degrees 0 to 350 Not Used e Enter Meter Position STA 1 to 12 after envelope insert station e Enter Meter Output Point Option PT 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 Postal Meter 3 e Enter Meter ON in degrees 0 to 350 e Enter Meter OFF in degrees 0 to 350 Not Used Enter Meter Position STA 1 to 12 after envelope insert station e Enter Meter Output Point Option PT 1 Station 7 Select 2 Station 8 Select Default 3 Inserter E Stop 4 Station 1 Error 5
166. ne Code Reader Add 389 26066 400 Ink Marker Option Add 002K 07970 AC DC Inserter Control Add 750 26978 500 3208 Feeder Mechanical Interface Add 750 27576 500 3208 Feeder Electrical Interface Add 389 26413 401 Right Angle Interface I 9 Update 002D 08137 Control Panel 1 11 change power supply number item 18 I 13 change motor number item 3 change belt number item 17 I 15 change motor number item 2 change item 8 23 30 I 17 add item 14 15 16 I 19 add item 14 15 I 21 change item 5 number I 25 change AC Cord number item 3 1 27 change Mount Plate number item 4 change pulley number item 17 1 29 change Shaft number item 19 I 41 change Gear number item 22 I 61 update T J Line Code Read Option F add 002C 07968 Sensor Interconnect Cable Add 389 26062 300 AC DC schematic Added replacement for 186 2823500088 as 118 30307 600 8 19 2009 420 SERVICE MANUAL ISSUE 09 00 071 25287 400 E COVER 5 Sect 8 99 Sect B 8 99 Sect C 8 99 SectD 7 99 Sect E 8 99 SectF 12 00 Sect 8 99 SectH 8 99 SectI 12 00 420 SERVICE MANUAL 071 25287 400 E ISSUE 09 00 COVER 6 SECTION A INTRODUCTION A 1 REQUIRED MANUAL N 2 A 2 Introduction to the manual 2 A 3 Introduction to the machince
167. ng the trailing edge of the document even with the center line of the lower most forward shaft accomplishes 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 spaced in the Transfer conveyor G 5b Position of the outfeed guides It 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 ISSUE 09 00 INSTALLATION SECTION PAGE 6 FEEDER GOOD POSITION POOR POSITION PACK TOO LOW POOR POSITIO Gripper Arms Orientation to 420 Figure G 6 G 5c Fold quality Constant fold quality is required or the package size can vary enough to cause the Transfer conveyor packages to be improperly positioned in the conveyor G 5d Ifa package spacing problem occurs If package spacing problems occur in the Transfer conveyor it should be purged of all the remaining documents in it This will insure that documents will be properly positioned G 5e Configuration of Exit sensor module The Ex
168. no accepted standard for 16 bit date transfers Since instruction fetches can be word accesses user programs can only be executed from internal memory The unused line CNTRL pin 50 on the STD Bus is commonly used by CDI for DMA request inputs to STD Bus CPU boards This is done for the CPU 186 The chart below illustrates the STD Bus connections with the CPU 186 PRINTED WIRING BOARDS SECTION E PAGE 7 SMART FEEDER SERVICE MANUAL ISSUE 09 99 PRINTED WIRING BOARDS SECTION PAGE 8 STD BUS J1 module has become an industry and IEEE standard The STD BUS INTERFACE FOR CPU 186 STD BUS following diagram shows the SBX connections on the CPU 186 DE 12 42 2 The CPU 186 is always the STD Bus master When the GND 5 mA 45 STD Bus is enabled by setting output bit 6 OP6 of the US DUART low BUSRQ periods are allowed This allows 2 bus other STD Bus peripherals to temporarily control the STD MPST 8 GND Bus A BUSRQ period is started with a peripheral setting A2 Sf RESERVED 10 NC its BUSRQ output low This will put the 80186 xi 7 EO WINTER 9 INTO microprocessor in a hold state and disable the STD Bus outputs except for MCSYNC CLK and BUSAK BUSAK IWR MINTRO 14 INTO going low signals the peripheral the STD Bus is free for RD 16 ARDY use No CPU 186 peripherals can be accessed by this GND IE as temporary STD Bus master hoon Excessive use of BUSRQ can int
169. nveyor not connected INVALID CONV CABLE gt Transfer conveyor cable damaged UNEXPECTED DWN Power down mistake Power key hit to shut machine off too soon second after hitting to power up STATE DIDN T CHANGE During power up sensors did not clear paper Check for paper jams jam Check state of all sensors in machine WDT CAUSED RESET Watchdog timer reset the program 1 Power down and restart O S TIME OVERUN Operating system did not have time to complete 1 Power down and restart all tasks 2 Check 5VDC and 24VDC power supplies short could be causing sensor problems B Contactthe technical support SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 41 SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 42 C 4 TROUBLESHOOTING C 4a SYMPTOM Error in feeder no sheet was fed A document entered the folder and did not exit or was not seen exiting Probable Cause Solution Paper was not seen by feed sensor Check feed sensor for dust Check adjustment of feed sensor adjust if necessary Check Input Test 1 19 LED on opto 0 0 should change Perform Feed Sensor RCP Paper not fed Perform Feeder RCP SYMPTOM Error in feeder short sheet A document entered the folder and did not exit or was not seen exiting Probable Cause Paper did not reach accumulator Feed sensor Solution Check that sheet length is properly set
170. o the FOLDS CHART Figure D 12 to determine set up of fold plates for your application The first fold line from the lead edge of the material will always be created by the lowest number fold plate selected from the fold chart The second fold line from the lead edge will be created with the next highest number fold plate from the chart If a third fold line exists this fold will be created with the highest number fold plate from the chart Example Using fold plates 1 and 3 Fold plate 1 will create the first fold from the lead edge and fold plate 3 will create the second fold from the lead edge 3 Lift folder cover and lift fold plate 1 up and back to remove it allowing access to fold plate 3 4 Lift fold plate 3 up and back to remove it from folder D 7e1 NAME AT THE TOP A HALF FOLD TOP EDGE V B LETTER FOLD EOGE Feed form face down Bottom edge leading Z to A collation Use Plate 1 Plates 2 3 and 4 are deflected Feed form face down Bottom edge leading Z to A collation Use Plate 1 1 3 and Plate 3 1 3 Plates 2 and 4 are deflected A POSITION FOLD PLATE 3 NAME AT THE BOTTOM HALF FOLD TOP EOGE LETTER FOLD TOP EDGE 5 Loosen the thumbscrew on the Fold Stop Feed form face up Bottom edge leading Z to A collation Use Plate 2 Plates 1 3 and 4 are deflected Feed form face up Bottom edge leading Z to A collation Use Plate 2 1 3
171. ock before tightening the read sensor locking screw 5 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 variations may cause the read sensor to see only CErFTINN 7 NN SECTION A ALZAS Z Read Probe Assembly Figure GBR Line Code Probe Assembly SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 29 SMART FEEDER SERVICE MANUAL ISSUE 09 00 D 4b2 Smart Feeder Line Read Setup Screens The screens displayed here are found after pressing the READ button under the SETUP menu Proceed to section D4 b3 to proceed with Line Read Setup Smart Feeder Reader Screens ON OFF SETUP READ TYPE TEST Page Setup Reader Setup WHTLVL mir CUSTOM SETUP REPAIR INFORMATION SECTION D PAGE 30 WHT LVL 00 OFFSET 22 000 LAMP 000 BLK LVL CURRENT VOLTAGE 0 00 TRIP POINT OFFSET 1 000 TRIP POINT 1 000 CUSTOM SETUP 1 7 GAIN enter gain value 2 7 OFFSET 1 OFFSET 1 000 3 7 OFFSET 2 OFFSET 2 000 4 7 LAMP LAMP SETTING 000 5 7 TRIP POINT 1 LOW TO HIGH TRIP POINT 1 SETTING 000 6 7 TRIP POINT 2 HIGH TO LOW TRIP POINT 2 SETTING 000 7 7 LEAD EDGE COUNT LEAD EDGE COUNT 000 D 4b3 Setting Up th
172. ode misprinted BLANK PAGE No bar code was found within first 3 inches of Blank page travel Page is backwards or upside down Misread Misprinted bar code Read was not reported in time refer to Section C2 d DUMP TO FEED DELAY TIMER SETUP The rest of the package is missing Misread Bar code misprinted Two identical pages were printed Misread Misprinted bar code SHORT GROUP End of group mark was encountered before the last page in the group was seen DUPLICATE PAGE Two consecutive page s entire bar codes were the same Paper skewed under read sensor The pages are switched or missing Misread Misprint of bar code INVALID GROUP Group sequence has changed within a 1 Misread SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 33 PAGE OUT OF SEQUENCE _ The page numbers within the package are not in sequential order SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 34 o to group out of sequence 2 Bar code misprinted EXPECTED PAGE ONE Package stopped in accumulator Min or max value for package incorrectly set up Up Down sequence incorrectly set Bad code GROUP OUT OF RANGE A page from another group is mixed in with the same page number Misread PAGE OUT OF RANGE ithi i The pages within this group are switched or missing Misread INVALID COMMANDI Reader board did not understand command Shut down and check that all bo
173. omponent is out of line or deformed a small amount of oil may be used as a short term fix to eliminate noise or binding until the component can be replaced SECTION C PROBLEM ANALYSIS Machine Diagnosfi gu u renti ete rei kata ha iv ee PER rhe vnd ina bra reo 2 2 Screen Operation essssssesssesnssnsssnssnnesnnennssnsssnnsnnnsnnsnnnsnnssnnssnnsnnsnnnsnnnenn 2 2 INPUT TEST MENU S icto 3 C 2b OUTPUT TEST 5 C 2c SPEED TEST MENU eere erbe 6 C 2d SETUP TEST MENU terere ss sn 6 2 CYCLE LEST MENU deir aethere oles ebay 11 C2f INSERTER TEST 11 C2g POSTAL METERING SETUP PRESETS een 14 C 3 Software Error Codes uessessnsssssssnsnnsnssnnsnnsnssnnsnnsnssnnsnnsnnsnnsnnsnnsnnsnnnee 18 General Solutions to Errors sese 18 C 3b Solutions to Less Common Errors eee 19 C 3c Specific Errors Causes and Solutions 19 C 4 Troubleshooting 42 4 SYMPTOM Error in feeder no sheet was fed 42 C 4b SYMPTOM Error in feeder short sheet 42 C 4c SYMPTOM Error in feeder long sheet 42 44 SYMPTOM Error in feeder two sheets 43 Read errors 41 4 4 0 43 4 SYMPTOM
174. 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 SMART FEEDER SERVICE MANUAL ISSUE 09 00 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 Sensor Figure REPAIR INFORMATION SECTION D PAGE 13 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 14 D 3 REPAIR CHECKOUT PROCEDURES RCP EDURE FOR PAPER COULD NOT BE 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
175. ons including inside the Folder Remove any paper or obstructions Feed a sheet through the machine to confirm that alignment adjustments are correct ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE2 ON the Smart Feeder press RESET ON and confirm the following e All drive belts are moving e Sensors are not blocked or fouled e Machine operating parameters set correctly e 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 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 D 1b List of Repair Checkout Procedures RCP REPAIR CHECKOU REPAIR CHECKOU REPAIR CHECKOU REPAIR CHECKOU REPAIR CHECKOU REPAIR CHECKOU REPAIR CHECKOU REPAIR CHECKOU REPAIR CHECKOU REPAIR CHECKOU REPAIR CHECKOU REPAIR CHECKOU REPAIR CHECKOU REPAIR CHECKOU REPAIR CHECKOU SMART FEEDER SERVICE MANUAL T PROCEDU T PROCEDU T PROCEDU T PROCEDU T PROCEDU T PROCEDU T PROCEDU T PROCEDU T PROCEDU T PROCEDU T PROCEDU T PROCEDU T PROCEDU T PROCEDU T PROCEDU RE FOR PAPER COULD NOT BE EED
176. or sensor need adjustment SHEET WAS TOO LONG A sheet was measured longer than expected Two sheets were fed shingled thus increasing the apparent document length The user selectable length is too short The feed sensor needs adjustment The pullout rollers in front of the singulator need adjustment Paper of debris left on feed sensor upon power up EXTRA SHEET WAS FED Two sheets fed together more than one sheet s Two or more sheets were fed thickness was detected at the feed sensor The feed sensor needs adjustment see double detect sensor adjustment procedure There is excessive printing in the extreme left hand margin Feed sensor is block by dust BLOCKED FEED SNS Obstruction of feed sensor during power up The feed sensor needs adjustment The pullout rollers in front of the singulator need adjustment pS Paperduston sensor CONVEYOR TOO SLOW 1 Feed motor KBIC out of adjustment 2 Motor unplugged NV RAM DATA CORRUPT Data in the non volatile ram was changed 1 Power to the CPU 186 was unplugged directly at the board Noise in the 120 VAC power Battery jumper removed form CPU 186 NOT ENOUGH NV RAM Battery back up on the non volatile ram chip is 1 Ram needs to be replaced bad PRESETS CORRUPT Program error internal processing error number Should not occur If error is displayed cycle one 1 the main power switch off on If the problem persists contact GBR field service department Bad CPU 186 board FE
177. or 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 186 PWB Run the machine Check the singulator is it properly adjusted N UJU 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 D 4 GBR LINE CODE READ SYSTEMS OPTION D 4a Introduction e The Line Code Recognition System is capable of decoding line code marks that are on 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 a 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 Line 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 Smart Feeder s VIP
178. or to value desired and press ENTER FIRST is the first bit encountered when reading Page and Group marks can be arranged as Most Significant Bit First MSB or Least Significant Bit First LSB EXAMPLE LSB EXAMPLE MSB GRV GRV EOG EOG GS1 GS8 GS2 GS4 GS4 GS2 GS8 GS1 PS1 PS4 PS2 PS2 PS4 PS1 PAR PAR SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 43 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 44 15 17 CALIBRATION CHOOSE CODE CALIBRATE lt gt UNDO ENTER a Press READ on the Display Panel Move the cursor to OFF ON RECALIBRATE select reading On b Move the cursor to select Setup NOTE Calibration is normally to be used by the Move the cursor to choose Line Code Setup Then service technician only See section GBR Line Code Read for related information Use the cursor keys until the desired choice flashes Press ENTER Calibrate the machine by running a special calibration document through the machine The document has two precisely placed marks that are the reference points to calibrate the machine The numbers of encoder signals are counted by the computer The encoder signals are considered valid if the encoder signals counted are within 1296 of the expected number The first line code mark is placed one inch from the leading edge of the document The second line code mark is placed six inches from the first mark code mark No othe
179. p selector Manual group selection for 1 to 5 sheets SMART FEEDER SERVICE MANUAL ISSUE 09 00 INSTALLATION 071 25287 400 SECTION A PAGE 15 SMART FEEDER SERVICE MANUAL ISSUE 09 00 INSTALLATION 071 25287 400 SECTION A PAGE 16 Counter Modes Total count batch count resettable count 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 420 3 can also convert an intelligent continuous form mail inserting system to a cut sheet operation Controller Adjustable operators panel with readout and push button access to all system functions System is microprocessor controlled with self diagnostics and error display including double misfeed and jam detection Electrical Service 110 Volts 1 Phase 60Hz 9 Amp 220 Volts 1 Phase 50 or 60Hz 5 Amp 1 000 BTU hr Fuse List Refer to Section D10 Length 120 3048 mm Model 420 1 Width 26 660 mm Height 52 1321 mm Weight Net approx 350 Ibs 159 kg Read Options T J Line Code Bar Code 3 of 9 SMART FEEDER SERVICE MANUAL ISSUE 09 00 INSTALLATION 071 25287 400 SECTION A PAGE 17 SECTION B PREVENTIVE MAINTENANCE B 1 Test equipment and tools
180. parts Catalog as a reference when working on or ordering parts for the folder D7 h1 Belts 1 Remove the side covers 2 Slip the belt off of the pulleys 3 Put the new belt onto the pulleys D7 h 2 Sensors Speed Encoder 1 Remove the side covers 2 Unplug the sensor PWB 3 Detach the sensor PWB from the bracket 4 Loosen the set screws which secure the encoder disc to the shaft 5 Remove the encoder disc 6 Replace in reverse order 0 713 Bearings take rollers out from side of folder with speed encoder 1 Remove the side covers 2 Remove the sheet metal screws and bearing 3 Remove the bearing 4 Replace in reverse order D 7h4 Red handle 1 Loosen the three set screws from the shaft 2 Pull the handle off of the shaft 3 Replace in reverse order Remove three set screws Folder Handle Figure SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 75 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 76 REPAIR CHECKOUT PROCEDURE FOR FOLDER CIRCUIT BREAKER REFER TO SECTION F FOLDER POWER SCHEMATIC NOTE The folder motor switch breaker is mechanically locked ON and the control shaft has been removed Check the circuit breaker located in the Folder wall and check the folder fuse F4 Are they tripped blown 1 The motor is running but speed or timing is incorrect Y N Go to step 4 2 Check speed pot is it correctly set Check the Speed
181. pn ood 1 bo pt xi f a 1 d a i A S loooocooooooooocod OPTO RACKS FIGURE C 2 C 2b OUTPUT TEST MENU SELECT TEST ENTER ver 07625 xxx INPUT OUTPUT SPEED SETUP CYCLE INSERTER SELECT OUTPUT lt gt START MORE After pressing the TEST key the SELECT TEST message appears asking which test to perform Press the or key to scroll through the available choices until OUTPUT is highlighted Press ENTER to select The display will then indicate the status of the output 00 00 OFF NAME OFF ON or UNAVAILABLE Cycle the machine to change the output note that the output is operating Its state should change as indicated on the display Also the LED on the associated optical relay will be OFF or ON depending on the state of the input Rack Opto indicates the location of the associated optical relay Press to see information for each input as described below Located on Used for Part No SMART FEEDER SERVICE MANUAL ISSUE 09 00 Rack Opto 1 Feed Clutch 1 0 2 Feed Motor 1 2 3 Acc Dump Clutch 0 20 4 Acc Dump Brake 0 23 5 Folder Motor 1 1 6 Master Relay 1 3 7 Transfer Conv Clutch 0 21 8 Transfer Conv Brake 0 22 9 Separation Sol 1 inserter
182. process A metal wand monitors the paper level in the singulator area A two inch stationary orange roller rests above the feed belt SMART FEEDER SERVICE MANUAL ISSUE 09 00 in the center of the feeder and allows only the bottom sheet of paper to be fed while holding back all others A series of sensors monitors the flow of paper through the Smart Feeder 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 sensor 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 186 REPAIR INFORMATION SECTION D PAGE 5 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 6
183. r Components 75 D 8 Transfer Conveyor e eene enne 77 D 8a Description a iet 77 D 8b odere a COUR UE ER 77 D 8c Exit sensor Test on the Transfer conveyor 78 D 8d 420 configuration of Exit sensor module 78 D 8e Package overhang at last 79 D 8f Position of the Transfer conveyor s outfeed guides 79 D 8g Fold quality cc exse REPE RS 79 D 8h Transfer conveyor package spacing problem 79 D 9 POWER UNIT a 81 REPAIR INFORMATION SECTION D PAGE 1 SMART FEEDER SERVICE MANUAL D 1 INITIAL ACTIONS Initial Actions are used to gather information from the operator concerning problems in Smart Feeder 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 Smart Feeder AC power OFF Check all areas of the machine for paper or other obstructi
184. r absence of a package in the accumulator It also monitors package discharge when the dump clutch has been engaged 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 this contactor is wired to the E stop circuit on that external device e g Pinnacle A connection to the 420 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 420 For this E stop string to be functional a blue jumper across pins 24 and 25 ISSUE 09 00 Infeed Transfer Convevor INTRODUCTION SECTION A PAGE 12 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 will interrupt power to the conveyors and folder whenever a cover is opened e Under the cover located over the singulator mechanism e Under the cover located over the accumulator section e top cover of the folder
185. r barcode job is selected SHORT GROUP If page sequencing down and an end of group mark is seen besides the end of group on the highest page of the set before page 1 is reached this error will occur ERROR SUGGESTION 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 D 6 ACCUMULATOR SECTION 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 S detects paper arriving in the accumulator while the Accumulator Sensor indicates presence or absence of D 6b 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 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
186. r marks can be in the area between the two sets of marks To calibrate the reading system first make sure the feeder is operating properly Correct any problems before proceeding with the calibration move the cursor to choose Lines Per Inch Choose 6 or 8 as applicable See 12 17 d Move the cursor to choose Line Code Setup Then move the cursor to choose Calibration and again to choose Re calibrate See 15 17 e Exit the Read Menu Feed a single calibration document through the feeder and into the accumulator at normal speed Press and hold the CYCLE key to feed the document through the feeder AM If the calibration is good the display will show Good Calibrate and if the calibration is bad the display will show Bad Calibrate If a bad calibration is indicated select RECALIBRATE before another document is fed 16 17 TOLERANCE CHOOSE CODE TOLERANCE lt gt UNDO ENTER LOW HIGH 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 Use the cursor keys until the desired choice flashes Press ENTER 17 17 CODE FIELD FORMAT Use the cursor keys
187. ram error internal processing error number 1 Should not occur If error is displayed cycle the main power switch off on 2 If the problem persists contact support 3 Misprint of bar code YES NO EOG ARE SAME European Mismatched group marks cause 1 EOG and EOG marks same code in accumulator No EOG or EOG mark in same code 3 Misprinted bar code INSERTER ERRORS NV RAM DATA CORRUPT Data in the non volatile ram was changed 1 Power to the CPU 186 was unplugged directly at the board 2 Noise in the 120 VAC power 3 CPU 186 battery jumper removed NOT ENOUGH NV RAM Battery back up on the non volatile ram chip is 1 Ram needs to be replaced bad PRESETS CORRUPT Program error internal processing error number 1 Should not occur If error is displayed cycle SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 31 SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 32 one 1 the main power switch off on 2 If the problem persists escalate service LINE READ ERRORS NO RESPONSE TIMEOUT Blank page Read encoder failed paper jam Feed sensor out of adjustment GROUP OUT OF SEQ Two consecutive packages group number were Group s were missing not in the proper sequence 7 6 5 0 7 6 Misread Misprinted bar code Paper skewing under read sensor EXPECTED END OF GRP The end of group mark was expected but not The document sequence is out of order read Misread Bar c
188. rd However if the document is throughout the end of the Transfer conveyor then the interrupt is not being seen by the control card ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 78 NOTE The Interrupt signal enters the Control card CPU 186 at header J9 The signal comes from J10 a 50 pin in line ribbon cable header 0 84 420 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 Smart Feeder SENSOR MODULE EXIT SENSOR Transfer Conveyor Exit Sensor Figure D 8e 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
189. rks in same code in accumulator ROLL 7 OUT OF SEQ Documents stalled in accumulator Current page number is greater than computed cumulative count 2 Current page number is less than computed cumulative count 7 SHEETS AND NO Accumulator full group not complete No EOG mark accumulator full No subset count in setup NO RANDOM CHECK MK Incorrect document in accumulator ET check mark not set correctly in So UNEXPECTED RAN CHECK 2 Code bad or misprinted ID CHANGED IN SET does not belong to group Document out of sequence Code bad Code misprinted 1 2 LAST SET SAME ID Package stalled in accumulator 1 Group ID out of sequence 2 Incorrect setting for Group Sequence 1 SamesetsOK SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 37 SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 38 TRANSFER CONVEYOR ERRORS JAM INTO CONVEYOR Documents have jammed in the transfer More than the acceptable number of conveyor documents entered the transfer conveyor and did not exit into the accumulator The transfer conveyor infeed sensor needs adjustment or cleaning of paper dust The accumulator presence sensor needs adjustment JAM IN CONVEYOR T Documents have jammed inside Transfer Documents have entered but not exited the Conveyor Transfer Conveyor The exit sensor is out of adjustment The transfer conveyor sensor is out of adjustment Paper dust on sensors
190. ry adjust the Fold Stop Level thumb wheel until the measurement on each of the fold plate scales is exactly the same 20 Insert the open end of fold plate 42 back into the folder making sure that the fold plate rests on the fold plate stops D 7e4 POSITION FOLD PLATE 4 NOTE IF IT IS DETERMINED FOLD PLATE 4 SHOULD NOT PERFORM A FOLD CONTINUE WITH STEP 21 IF FOLD PLATE 4 WILL PERFORM A FOLD SKIP STEP 21 AND GO DIRECTLY TO STEP 22 21 Insert the deflector end of fold plate 4 into the folder Make sure that fold plate 4 rests on the fold plate stops GO TO STEP 27 22 Loosen the thumbscrew on the Fold Stop 23 Slide the Fold Stop so its front edge lines up with the appropriate setting on the Left and Right Fold Plate Scales for fold plate 4 24 Tighten the Fold Stop thumb wheel 25 If necessary adjust the Fold Stop Level thumb wheel until the measurement on each of the fold plate scales is exactly the same 26 Insert the open end of fold plate 4 back into the folder making sure that the fold plate rests on the fold plate stops SMART FEEDER SERVICE MANUAL ISSUE 09 00 27 Turn the folder hand wheel and turn it clockwise to manually feed a sample piece of material completely through the folder 28 Check to see if the folds are straight If they are straight the set up is complete If any fold is not straight continue with step 29 29 Turn the Fold Plate Fine Adjustment Thumbscrew for any of th
191. s e Check for correct feed speed e Check speed sensor for proper operation N Check for failure on the CPU replace as necessary e Bad e Bad software D 5 3 OF 9 LASER BAR CODE READ OPTION D 5a 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 a 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 however 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 Do not attempt to defeat any safety provisions SMART FEEDER SERVICE MANUAL ISSUE 09 00 COMPLIES WITH DHEW REGULATION 21 CFRSUBCHAPTER J y mw D
192. s 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 3 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 D2 c6 Auxiliary Feed Belt Adjustment The auxiliary feed belts are adjustable by angling the back end up or down The auxiliary feed belts assist the main feed belt when variations in frictional quality are encountered and the feeding of paper becomes erratic The auxiliary feed
193. s 1234 and Weight Inserts 5678 the document will be stamped by the appropriate postal meter The dollar value must be manually entered in the postal meter 1 Enter the weight of the individual document in the PF300 in 16 Weight Page and Envelope SMART FEEDER SERVICE MANUAL ISSUE 09 00 2 Enter the weight of an individual envelope in 16 Weight Page and Envelope 3 Enter the weight of each insert in stations 1 4 17 Weight Inserts 1234 and stations 5 8 18 Weight Inserts 5678 4 Enter the upper weight limit of the entire envelope package for postage meter 1 and 2 in 15 Postage Meter Weights 5 Enter ON at xx value for 5 Postal Meter 1 12 Postal Meter 2 and 14 Postal Meter 3 Normally these value are 200 240 and 280 respectively If one of these values must be changed the others should also be changed to remain 40 apart from each other 6 Enter OFF at 010 for Postal Meter 1 2 and 3 7 Enter the Postal Meter Station STA 00 see Postal Meter 1 2 and 3 8 Enter the postal meter output point to the 420 see Postal Meter 1 2 and 3 The 420 will total the weights of all documents inserts and the envelope and then send it to the correct postal meter 5 Postal Meter 1 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 should then be set to
194. s out of sequence properly Check sequence count in read setup Up Down Off Check setup voltages to ensure dots are not being seen as lines verify by running stock with scope connected to read bd C 4n SYMPTOM Error in read expected page one First page of package out of sequence Probable Cause Solution While counting page sequence down or roll sequence number 1 Inspect stock for packs out of sequence page one was not seen Check sequence count in read setup Up Down Off Check setup voltages to ensure dots are not being seen as lines verify by running stock with scope connect to read bd Perform Reader Board RCP 4 SYMPTOM Error in read group out of range Package improperly coded NOTE This error should only occur in special code 4 SYMPTOM Error in read out of range Package improperly coded NOTE This error should only occur in special code Generally someone has changed the Min Max in AirTec code C 4q SYMPTOM Error in read presets corrupt Package code can not be read Probable Cause Solution The stored values for reading have been lost Check main CPU hardware for failure Check CPU for bad battery or battery jumper missing SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 47 SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 48 C 4r SYMPTOM Error in read yes no eog are same Read system corrupt
195. s paper over the read probe you will see voltages increment and decrement on the screen When the sensor is over the white portion of the paper the voltage reading on the screen should be about 5 When a black line from the line code is over the read probe the voltage reading on the screen will be O Also while you are performing this step make sure that the read probe is entirely covered by the line code If the line code does not entirely cover the read probe the reader will not work properly After pressing ENTER the voltage values will no longer increment and decrement on the screen when changing from black to white Exit out of this screen 7 Go to TRIP PT and press ENTER a Remove paper from the light beam and press ENTER When the system beeps to indicate that it is done some numbers will be placed on the screen next to TRIP POINT 1 and OFFSET 1 e TRIP POINT 1 value should be between 40 and 150 ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 32 e OFFSET 1 should be between 100 and 250 b Exit out of this screen and go to the next step 8 Press the READ button and go into SETUP gt READER SETUP gt CUSTOM SETUP gt 2 7 OFFSET 1 gt Press ENTER and record OFFSET 1 value 9 Go to 3 7 OFFSET 2 gt Press ENTER and record OFFSET 2 value 10 Find the average of the recorded OFFSET 1 and 2 values 11 Change OFFSET 1 and 2 value to this average value by pressing the or keys example OFFSET
196. signal 1 5 10 Separation Sol 2 inserter signal 1 8 11 Separation Sol 3 inserter signal 1 9 12 Separation Sol 4 inserter signal 1 10 13 Separation Sol 5 inserter signal 1 11 14 Separation Sol 6 inserter signal 1 12 15 Separation Sol 7 inserter signal 1 4 16 Separation Sol 8 inserter signal 1 16 17 Separation Sol Encoder inserter signal 1 13 18 Ink Marker Solenoid inserter signal 1 14 19 Env Sns Dis inserter signal 1 15 20 Emr Stop inserter signal 1 16 21 Ins Station 1 Error inserter signal 1 17 22 Postal Meter divert inserter signal 1 19 23 Paper Hopper Request 1 18 24 First Hold Clutch 2 15 25 First Hold Brake 2 14 26 Feeder Brake 2 13 PROBLEM ANALYSIS SECTION C PAGE 5 SMART FEEDER SERVICE MANUAL ISSUE 09 00 C 2c SPEED TEST MENU SELECT TEST ENTER ver 07628 xxx INPUT OUTPUT SPEED SETUP CYCLE INSERTER FEED 165 FOLD 115 DEMAND OFF READ 150 ALL SPEEDS IN IPS EXIT TO LEAVE OR Note IPS inches per second The speeds indicated are approximate Press the ENTER key to start motors Press the EXIT UNDO key to stop motors NOTE The FEED and READ speeds must be within 5 of each other to ensure normal operational condition C 2d SETUP TEST MENU SELECT TEST lt gt ENTER ver 07625 xxx INPUT OUTPUT SPEED SETUP CYCLE INSERTER SELECT SETUP UNDO EXIT After pressing the TEST key the SELECT TEST message appears asking which test to perform Press
197. st Menu Speed Test Menu Setup Test Menu Cycle Test Menu Inserter Test Menu Software Error Codes Troubleshooting SECTION D REPAIR INFORMATION Repair Checkout Procedures Feeder Section GBR Line Code Read including screen menus and error codes Laser Bar Code Read including screen menus and error codes Accumulator Section Folder Section includes parts lists SECTION E PRINTED WIRING BOARD INFORMATION SECTION F MACHINE SCHEMATICS SECTION G INTERFACE TO OPTIONAL EQUIPMENT Connecting to an Inserter SECTION H MISCELLANEOUS SECTION I PARTS 420 SERVICE MANUAL ISSUE 12 00 COVER 071 25287 400 E 3 2 HEADERS FOOTERS The information listed along the left edge refers to the stated machine In the following example the document is the Service Manual for the BH 6000 machine TP50429 is an index number which allows Bell and Howell to track its documents The particular issue listed in the center is an internal tracking device which allows Bell and Howell to make document revisions If the issue is revised Rev gt appears below the issue 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 GLOSSARY A glossary of terms defines and explains all acronyms abbreviations and symbols used in the manual The glossary lists terms which are cross referenced to other terms within the manual 4 TAB
198. supply Clean the sensors Do the LEDs come on Y N e Replace the sensor SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 19 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 20 REPAIR CHECKOUT PROCEDURE FOR PAPER JAM IN FEEDER Clean the sensors Do the LEDs come on Y N Check sensor connections 4 e 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 Check that the Smart Feeder 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 pe blocked by a sheet of paper v 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 the a sheet blocking the sensor Check that printing on the stock is not interfering with the sensor Does the au
199. 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 ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 46 D 4f2 High Tolerance Windowing 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 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 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 0 494 Recommended Line Code Configuration Below is a description of the data fields recommended in a Line Code to
200. the or key to scroll through the available choices until SETUP is highlighted Press ENTER to select PROBLEM ANALYSIS SECTION C PAGE 6 1 TWO SHEET DETECT DISABLE TWO SHEET CHECK UNDO EXIT ON OFF 2 EXIT CONTROL SELECT 0 3 CHOOSE TYPE LOWER LEFT DISPLAY 1 5 Total Sheets 10 11 12 13 CREEPER ONLY 470 BULK CUTTER CONT HIGH COUNT STOP 1 10 UNDO EXIT PERFORMANCE lt gt UNDO EXIT OFF ON INSERTER ONLINE OFFLINE Enter FIRST PAGE HOLD DELAY 2 5 Total Packages 3 5 Page in Package 4 5 OMR 5 5 No Display 4 CHOOSE TYPE LOWER RIGHT DISPLAY 1 6 Batch Sheet 2 6 Batch Package 3 6 Inserter Rate Hour 4 6 Ave Wait for Demand 5 6 OMR 6 6 No Display 5 CHOOSE NO USE SHUTDOWN TIME LENGTH 1 5 10 15 OFF 6 PULSE FEEDING ENABLE 14 15 16 17 18 FIRST PAGE HOLD DELAY 05 CONFIG 0 NOTE Cycle machine power to set change XFER CONVEYOR W INSERTER STRAIGHT CONVEYOR XFER CONVEYOR STAND ALONE XFER CONVEYOR W INSERTER P DUMP TO FEED DELAY TIMER SETUP DUMP TO FEED 10 DUMP BRAKE 05 DUMP DELAY TIMER SETUP DUMP DELAY TIMER VALUE 25 SERIAL COMMUNICATION PROTOCOL SERIAL COMM PROTOCOL NUMBER 0 5 FEED BRAKE ENABLE DISABLE PULSE FEEDING ENABLE UNDO EXIT ON OFF 7 CHOOSE TYPE TRANSFER CONVEYOR TYPE TRANSFER CONV lt gt UNDO EXIT GRIPPER ARM HOPPER FILL OPEN FEED 8 DISPLAY BELL DISABLE DISPLAY BELL UNDO EXIT ON OFF
201. the value of the single digit place O being the shortest time and 9 the longest time allotted for a reading This should be set as low as possible without causing a Blank Page error The tens digit place is only used in setting the amount of time from an accumulator dump to when the next sheet is fed It does not affect the time allotted for a reading The single digit place however does affect the feed delay time DUMP BRAKE is normally set to 5 ms This time period is a delay in energizing the Dump Brake after a package has left the accumulator section and into the folder section This delay allows the package to clear the dump rollers before the Dump Brake is energized Should the trailing edge of the package get stopped in the dump rollers increase this time until the package clears the rollers The range of this variable is O to 99ms but should be kept as short as possible to not effect performance 16 18 Dump Delay Timer Setup is set to 25 for normal run and 40 when First Page Hold is being used PROBLEM ANALYSIS SECTION C PAGE 9 SMART FEEDER SERVICE MANUAL ISSUE 09 00 PROBLEM ANALYSIS SECTION C PAGE 10 17 18 Serial Communication Protocol If RS232 communications to an external device will be used the correct external device protocol must be selected No external device RR Donnelly Short message output RR Donnelly Long message output Pinnacle old message output Pinnacle new EDA 5109 message output Gener
202. the documents correctly in the Accumulator package in the accumulator It also monitors for successful package discharge when the dump clutch has been engaged SMART FEEDER SERVICE MANUAL ISSUE 09 00 1 1 r nh aco U sul Gar ES Deals 0 NAL an Setting for Brake 005 lt u IU DIURC JUJ Accumulator Clutch Setting Figure REPAIR INFORMATION SECTION D PAGE 61 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 62 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 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
203. ty is set at ODD EVEN or NONE 7 17 END OF SUBSET END OF SUBSET lt UNDO ENTER ON OFF BY COUNT Use the cursor keys lt gt until the desired choice flashes Press ENTER 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 8 17 RANDOM CHECK MARK RANDOM CHECK MARK lt UNDO ENTER ON OFF 9 17 BLANK PAGE ERROR DISABLE BLANK PAGE ERROR UNDO ENTER ON OFF Use the cursor keys lt gt until the desired choice flashes Press ENTER 10 17 NUMBER OF WINDOWS CHOOSE NO of WINDOWS lt gt UNDO ENTER 1 2 Use the cursor keys lt gt until the desired choice flashes Press ENTER Select the number of read windows required Currently this must be set to 1 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 41 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION 11 17 WINDOW SETUP ENTER WINDOW to SETUP UNDO ENTER 1 2 WINDOW ONE lt gt UNDO ENTER BEGIN HT LENGTH WINDOW TWO lt gt
204. uding the halo should be equal to the width of a solid bar 0 020 inch 0 003 and 1 4 to 3 8 inch 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 2 Place a document with the GBR line code near the light from the read sensor 3 Turn the read lamp on Press the READ button and go into SETUP gt READER SETUP gt CUSTOM SETUP gt 4 7 LAMP Enter LAMP SETTING 255 by pressing the or keys 4 Loosen the read sensor locking screw and push the read sensor completely into the UNS housing Observe the light beam image It gt HE 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 N come more and more into focus Proper PAPER GUIDE RAIL wa focus is obtained when the image is at its smallest partial code resulting in a read error 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 bl
205. uld never appear if it does it means that there is a bug in the program NO RESPONSE BLANK PG The reader did not return a reading the proper amount of time ERROR SUGGESTION Make sure that the barcode reader is lined up with the code Make sure that the barcode print on the paper is good quality JOB CHANGED IN RUN The page that was just read did not have the same group job number as the other pages within that set ERROR SUGGESTION the job did not change within the set check to see that the proper barcode is printed on the page and that the barcode matches the specifications SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 59 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 60 Check to see that the proper barcode job is selected GROUP DID NOT CHANGE Ifthe last set group that passed has the same number of the next set group this error will occur ERROR SUGGESTION If the group did change within the 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 BAD CHECK DIGIT The check character read in the barcode did not match the software s computed check character for the read barcode characters ERROR SUGGESTION Check to see that the proper barcode is printed on the page and that the barcode matches the specifications Check to see that the prope
206. umber of solid marks within a code Note The fields that are marked Optional can be eliminated by operator configuration of the machine However when a data field is eliminated package security and integrity suffers REPAIR INFORMATION SECTION D PAGE 47 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION D 4h Specifications of the Line Code System The Print Contrast Ratio should be at least 6596 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 required at the lead edge of the Gate mark 0 332 Clear area required at the trail edge of the code 0 166 SECTION D PAGE 48 D 4h1 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 REPAIR CHECKOU
207. until the desired choice flashes Press ENTER 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 SMART FEEDER SERVICE MANUAL ISSUE 09 00 REPAIR INFORMATION SECTION D PAGE 45 SMART FEEDER SERVICE MANUAL D 4f Read Tolerance Selection The Line Code Recognition system supports two print 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 D 4f1 Low Tolerance Windowing 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

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