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SECTION 3 - SERVICE OPERATIONS

1. Retaining Ae screw I ee A oe GN m p u pe ae Bearing _ e Drive belt ha 9 Zi Wetter thumb 7 x screw Solenoid Bearing 10 Fig 21 Drive belt replacement Gain access to the drive belt by removing the cover over it slacken but do not remove the two retaining screws through the access holes on the front face Use a 3mm extended Allen key to undo the screws Lift the cover up and off Slacken the collar on the drive pulley and remove the circlip on the driven pulley Slide both off the shafts together with the belt Fit the new belt in reverse order to removal Conveyor belt replacement 1 Remove the drive belt and pulleys as described above 2 Lift off the carrier assembly located on the T rests 3 Lift out the wetter assembly by undoing the wetter thumb screw Page 3 20 Issue 1 Sep 2013 Remove the 2 retaining screws shown in Fig 21 and slide the whole unit forwards to clear the rear unseen spigots Unplug the ribbon cables a
2. BOG TOP Eg ir Lay Page 3 32 Issue 1 Sep 2013 Note that the QX Hawk mount should be allowed to drop to the lowest position on the vertical head bracket as shown in the assembled image below END STOPS SHOULD BE ALLOWED TO DROP TO THE LOWEST POSITION The vertical head bracket B8616P can be mounted in the orientation as shown using the same fixing components that are used on the standard head carrier assembly Connect the QX Hawk to the barcode interface PCB 180 711 using cable 182 8666 The QX Hawk must be connected to J1 LHS on the PCB Any other reader will then be connected to J2 RHS Hardware Software Setup Install the latest upgrade of software and firmware from the web site Note that s f must be higher issue level than the following Software version number 6 7 0 3 Firmware version number DS 1000 V10 02 00 00 DS 1200 V00 02 00 00 Open the IMOS application Page 3 32 DS 1200 G3 Service Manual Adding a second reader Go to the hardware set up screen and add a 2nd reader In the Extra settings tab select Reader on channel 1 to QX Hawk If you have moved a second reader from channel 1 to channel 2 you will also need to select the reader type for the second reader The screen dump below shows the co
3. Chassis screws Chassis screw ee IR t Ho j i S 4 RE CS oke E BE DE Hk EE SE a a F SST LL se hig e S rs zm e i 23 rb i om 8 Tt PCB screws Fig 24 Remove the drive shaft assembly with the 4 rollers by taking off the bearing housings and bearings Note the bearings may be secured with Loctite if so knock the end of the shaft to break the seal The bearings will then have to be replaced order part no E1054A Re move the springs with the shaft and also the locating screws in the chassis bridge Remove the pivoting sensor plate above the drive shaft complete with the pivots Remove the lock plates at the top of the chassis one with micros witch Remove the drive motor Unclip all wiring from the chassis and remove the P clips with plastic rivets All parts have now been removed Reassemble them all to the new assembly in reverse order to removal and fit the assembly to the ma chine Page 3 22 Issue 1 Sep 2013 3 5 ENVELOPE OPENER BEAM The envelope opener uses a pivoting extruded beam to catch the partly open envelope flap opening it fully The beam pivots back and forth very rapidly between constraints so to reduce noise rubber pads are attached to the faces of the constraining brackets The rear bracket is adjustable with a default factory setting as shown in Fig 25 below This setting is appropriate for most envelopes but in time it may stray and impair performanc
4. The procedure is different for OMR and barcode With OMR a calibration sheet must be used and the machine must be OMR calibrated when setup is complete With barcode no calibration sheet or procedure is required Instructions for creating a calibration sheet can be found in C Program Files PFE AutoMailer 5 Documentation Other Documenta tion Test Documents Calibration Sheets Note that ideally the calibra tion sheet should be printed from the same printer as the stationery OMR calibration is described on the following page Select the job on which the reader is to be set up and load a calibration sheet into the feed tray OMR or paper with label printed barcode In the Run screen press the unit which has the reader fitted to display the fine tuning screen Press Load to reader and follow the instructions to feed a calibration sheet under the reader Assuming the selected unit has OMR or Barcode reading enabled the Reader Setup tab will be present The setup procedure must be followed before reading can be used Reader setup Unit 4 Collator Confiquration not correct Reader on Ch 1 MS9 Reader Head 1 X Percent Read Test Decodes Sec Test Page 3 30 Issue 1 Sep 2013 Setup Procedure Ensure all covers are closed and the unit is switched on On the screen select whether OMR or barcode If OMR is selected press the Number of Marks button and enter the required numbe
5. see Fig 18 below All can be replaced in situ Turnover conveyor belts These can be slipped off the pulleys after loosening of the upper enve lope guide retained by 2 screws either side on the front vertical face It is not necessary to remove the guide completely Eject conveyor and drive belts Both of these can be wound off the pulleys to remove Note the direc tion of the pawls on the conveyor belt Turnover con Eject conveyor veyor belts Sg ma belt T gt Sel Upper Sr o Envelop o w Lower Envelope guide Turnover m drive belt Page 3 17 Issue 1 Sep 2013 Turnover drive belt The turnover drive belt can be replaced with the turnover in place 1 Remove the turnover conveyor belts as previously described 2 Remove the upper envelope guide 4 screws on 2 posts On the drive shaft remove both of the outer pulleys by taking off the circlips Also pull out the drive pins and remove both bearing housings 4 Work the belt off the end of the freed shaft Fit the new belt and replace all items in reverse order to their removal Page 3 17 DS 1200 G3 Service Manual 3 3 7 ENVELOPE CONVEYOR BELT REPLACEMENT The envelope conveyor contains 2 conveyor belts and 2 drive belts All can be replaced with little or no disassembly by removing the envelope conveyor from the opener unit Conveyor removal Raise the clamshell on the opener unit to gain access to t
6. BELT 1 ST COMM8993 9110888H BELT 2 ST COMM9268 9110889 RECTIFIER 2 ST COMM9359 9110890K BELT 1 ST CT 12 02 B01 W 9110891L COUNTER BLADE 1 ST CT 12 02 B02 W 9110892M GUILLOTINE BLADE 1 ST CT 12 02 B15 W 9110893N GUILLOTINE BLADE 1 ST CT 12 07 A96 _9110894P ROLLER at Traction Group 4 ST CT 18 01 C03 _9110895Q CIRCULAR KNIFE 6 ST CT 18 01 C23 DX 9110896R RIGHT GEAR 2 ST CT 18 01 C23 SX 91108975 LEFT GEAR 2 ST CT 18 01 C39 91108987 TRANSPORT ROLLER 4 ST MG 03 12 9110899U TRANSMISSION ROLLER 1 ST R 0024 9110900V GEAR SHAFT GROUP 1 Page 3 49
7. Page 3 24 Issue 1 Sep 2013 9 The transmitter button will now operate the relay Remote Transmitter Overlay The hand held remote has a purpose made overlay fitted which alters LEARN SWITCH LEARN LED POWER LED the appearance of the standard Viper buttons The buttons translate from standard to IMOS versions as shown below RLY 2 Erasing Receiver s Memory 1 Press and hold the receiver Learn Switch for approx 10 seconds 2 When the Learn LED turns OFF all memory is erased NOTE You cannot erase individual Tx encoders Configuring Receiver Outputs The jumper links configure the outputs to be Momentary or Latching The jumper links are made removed by the small link cap placed over the pin header Standard Viper With overlay Transmitter applied Viper TX button IMOS Overlay number description Aalay Outputs Aly ve ava mva Mor Mom Mom Fateh The configuration shown in the picture above represents the third row of the table See Remote Transmitter Overlay right for relating the Relay Outputs to the remote control buttons Single Cycle Page 3 24 DS 1200 G3 Service Manual Page 3 25 Issue 1 Sep 2013 3 7 ENGINEERING SCREEN Hardware Setup The Engineering screen allows engineer functions in the three following This displays the current hardware setup of each feed unit on the ma areas chine and allows any setting to be changed Referring to the screen 1 Setup of exi
8. Sensors Tests the mechanical sensors Condition of sensor is indicated Note that sensor may correctly be shown as blocked depending on whether the flag or disc is interrupting it It is not normally required to check sensor voltage but to do so follow emitter wires back to connector on PCB GRN WHT for narrow angle YEL WHT for wide angle Push DC meter probes onto contacts in con nector housing voltage should be 0 1 to 0 8v with sensor clear gt 4 5v blocked Note that WHT wire is positive Switches This displays the state switches on the selected clear or blocked If the state remains unchanged when the switch is activated the switch is defective Reader Setup This is used to set up the OMR or Barcode reader See following page for details Miscellaneous This provides a read only display of the unit s total count In the case of the inserter head both feeder envelope and output counts are shown Component Failure If any component or sensor has failed it will need to be replaced Loca tions of all components and sensors can be found from the look up list in section 5 5 Motors Solenoids amp Switches or section 5 6 Sensors Important After testing positions of backstops separators etc may have changed Original positions may be restored by selecting Clear Machine and Restart from the Run screen Page 3 29 Issue 1 Sep 2013 Page 3 29 DS 1200 G3 Service Manual OMR Barcode Reader Setup
9. kk PM A ENN P P P UON WN Qty O D SC 64009162 SC 66000551 SC 66002565 SC 66002566 SC 66002568 SC 66002571 SC 69000307 SC 69003834 9105192Z 9105193A 9105194B 9105195C 9105196D 9105197E 9105198F 91051996 Page 3 48 FIBRE OPTICS AMPLIFER 12V 5V PWR SPLY BD EL 00 V 3 AC 3A MODULE EL 00 V 3 DC DRIVER EL OO V 3 KEYB DISPLAY ASS Y EL 00 V 3 PROX SENSOR ASSEMBLY 30 V LAMP JAM PHOT CABLE HNH kA kA kA kA kA Issue 1 Sep 2013 The following list shows only the parts recommended to be held for emergency breakdown requirements on the CEM Cutter Order part number A0302A NTL Part No SC 07050033 SC 08019941 SC 14004915 SC 15015070 SC 16016846 SC 21000985 SC 21014682 SC 24007216 SC 24016274 SC 24016275 SC 28018465 SC 49021873 SC 63005157 SC 63005310 SC 63005313 SC 63005501 SC 63005633 SC 66002545 SC 66002777 SC 69000431 SC 69003842 SAP Part No 9106695Q 9105148D 9105155L 9105164V 9105168Z 9105172D 9105176H 9105179L 9105180M 9105181N 9107013W 9109520H 9105184R 91051855 91051861 9105187U 9105188V 9107593A 9107612V 91064642 9108447Q Description RETAINING BLOCK TRACTOR PICK CAM FOLLOWER TOOTHED BELT MXL 80094 O RING OR4075 BRUSH PRESSURE SPRING TENSION SPRING CIRCULAR KNIFE UPPER BLADE 1 in 6 TUNGSTEN LOWER BLADE WIRE PAPER GUIDE DC MOTOR FUSE 15A SLOW 125V 10x38mm FUSE 10A SLOW FUSE 3 15 A SLOW FUSE 5A FUSE 6 3A SLOW ENCODER DC DRIVE EL 00
10. of conveyor belts and a drive belt and the procedure for replacement is similar This section de scribes the procedure for the shuttle with any differences highlighted It is not nessecary to remove the shuttle or kicker to replace the belts Drive belt replacement To replace the drive belt wind it off the motor pulley by turning the knob on the driven pulley see Fig 17 below Fit the new belt similarly Take care that the pawls on the conveyor belts do not contact any obstruction it is preferable to raise the unit first Conveyor belt replacement To replace the conveyor belts proceed as follows 1 Remove the drive belt as described above 2 Wind the conveyor belts off the rear pulleys by turning the knob as previously described Shuttle only Work the belts out of the gap between the front pulleys and the guide plates and remove them Note the sensor on the LH side will have to be unclipped in order to take out the belt 3 Fit the new belts as a pair not singly Ensure that the pawls are aligned 4 Refit the drive belt The belts will automatically move to their cor rect position when the machine is next run 7 Conveyor belts Drive belt Fig 17 Shuttle shown kicker is similar Page 3 16 DS 1200 G3 Service Manual 3 3 6 TURNOVER BELT REPLACEMENT There are five belts in the region of the turnover 2 turnover conveyor belts 1 turnover drive belt 1 eject conveyor belt and 1 eject drive belt
11. play is removed from the belts but they are not excessively tight Refit the feeder conveyor to the front of the feeder reconnect the motor cable and replace the end undercover Page 3 15 DS 1200 G3 Service Manual Remove the conveyor belts 2 Atthe non drive pulley end of the conveyor shaft remove the E clip on the inside next to the flanged bearing Slide the bearing inboard and work the shaft free of the conveyor 3 Fit the new belt and replace the shaft in reverse order to removal Ensure that the wavy washers one each end are properly in place Refitting the conveyors Refit the conveyors in reverse order to their removal When the bearing housings are in place fit the pulleys and ciclips back on the shafts then refit and tension the drive belt as previously described Points to note 1 The bearing housing at the RH end of the upper conveyor is re tained with countersunk screws all other housings use cap head screws 2 Ensure the large wavy washers are in place inside the bearing housings before assembling 3 Ensure the drive pins are in place on the shafts before fitting the pulleys for the drive belt 4 When fitting the tension springs on the lower conveyor do not tighten the nuts fully but ensure that at least one full turn is made after the locking insert has been reached Page 3 16 Issue 1 Sep 2013 3 3 5 SHUTTLE amp KICKER BELT REPLACEMENT The shuttle and the kicker each contain a pair
12. the tensioner adjustment screw and lift the belt out through the cutouts in the chassis There is no tensioner on the innermost belt and this should be slipped off the lower pulley and the belt removed through the cutouts Fit the new belts and re tension the outermost belt it should be tight with no perceptible play 6 Fit the folder unit back onto the machine and reconnect the cables Tensioner adjustment screw Page 3 13 Issue 1 Sep 2013 3 3 3 FEEDER INTERFACE BELT REPLACEMENT The feed interface contains two sets of conveyor belts upper and lower and two drive belts To replace any of them the feed interface must be removed from the machine Prior to this the feeder on the rear of the feed interface must be removed as described below 1 Remove the two side covers on the feeder and also the underpanel below 2 To reduce weight remove the feeder conveyor from the feeder as described in section 3 3 4 3 Remove the screw retaining the vertical flange either side of the feeder From underneath remove the screw either side retain ing the feeder to the angled support brackets screws are located inside the feeder 4 Onthe LH side pull out the power and signal lead connectors The feeder can now be lifted away from the machine Warning The feeder is very heavy lifting should not be undertaken with out suitable assistance With t
13. 013 Page 3 44 DS 1200 G3 Service Manual Page 3 45 Issue 1 Sep 2013 Single On line Interface The following list shows the parts recommended to be held for an E1571 Single On line Interface this unit is used with E1546AA E1562AA and E1564AA A full set of the parts can be obtained by ordering part no A0425A 230v 115v NTL Part No SAP Part No Description Qty A2819A 9107524D STOP ASSY 1 BO156A 9106378K GUIDE TAPE 12 BO165A 9106863Q GUIDE SPRING 2 F5000A 9104428D BELT 90XL 037 1 F5011A 9104439Q BELT 120XL 037 1 F5012A 9104440R BELT 190XL 037 1 F5014A 9104442T BELT 100XL 037 1 F5021A 9104448Z BELT 408XL 037 1 F5029A 9104452D BELT 200DXL 037 D SIDED 1 Note These holding spares are in addition to the consumable spares shown previously Page 3 45 DS 1200 G3 Service Manual Vertical Stacker Page 3 46 Issue 1 Sep 2013 If a Vertical Stacker is fitted the following spares are recommended to be held in addition to the main spares There are 2 sets avail able either with or without ink marker spares A full set of the parts can be obtained by ordering part no A0417A 230v 115v for machines with ink markers or AD416A 230v 115v for machines without A0417A With ink markers NTL Part No SAP Part No 117 240 9100130B 179 8780 9107427C 180 745 9107019C 180 180 790 9105270F 181 079 9107462P 181 141 91008150 181 153 9107231Y BO174A 91055522 BO192A 9105551Y C4444A 91094815 E0237A 9103765N E0472A 9106275C AO 0
14. 104097 Pin dowel 3x24 EA 3 E5071A 9104133W Pin dowel 3 x 14 EA 10 E5074A 9104135Y Pin dowel 3 x 8 EA 5 E5098A 9104147L Pin dowel 3 x 18 EA 20 F4150A 9104398X Gear 40 tooth EA F4151A 9104399Y Gear feeder EA Page 3 39 DS 1200 G3 Service Manual Page 3 40 Issue 1 Sep 2013 NTL Part No SAP Part No Description Unit Qty F5003A 91044316 Belt Folder Fold Rollers 150XL EA 1 F5005A 9104433 Belt Envelope Opener 170XL EA 1 F5007A 9104435L Belt 200XL EA 1 F5011A 9104439Q Belt Folder Motor 120XL EA 1 F5012A 9104440R Belt collate 190XL EA 1 F5013A 9104441S Belt Envelope Opener 210XL EA 1 F5015A 9104443U Belt 230XL EA 1 F5022A 9105228M Belt 300DXL EA 1 F5024A 9105639Q Belt 290XL EA 1 F5029A 9104452D Belt collate 200DXL EA 1 F5101A 9104488R Belt Stepper STS 110T EA 1 F5102A 9104489S Belt 450DXL EA 1 F5107A 9104491U Belt 260 S2M EA 1 F5159A 9108392H Belt T5 50T 10 Wide with Pawls EA 1 F5163A 91052271 Belt HTD 425 Feeder EA 1 F5164A 9105226K Belt HTD 280 Feeder EA 1 G0178A 9105225 Sponge Wetter Roller EA 4 G1001C 9104606P Spring Bush EA 2 G1 0253 A 91064581 Fold Roller Spring EA 2 G1 0269 A 9108393J Collate Spring EA 2 G1001C 9104606P Spring Brush EA 2 G1025A 9104625 Spring pressure EA 2 G1026A 9104626K Spring Conveyor EA 2 G1054A 9104639Y Spring Holder EA 2 G1108C 9104679Q Spring Opener return EA 1 G1111A 9104681S Spring light green EA 2 G1116A 9104685W Spring medium yellow EA 2 G1160A 9104701N Spring No F
15. 5935 9109500M 9105605E 9105605E 9105606F Description Opto pair long range sensors Motor PCB Assy 5 Sen 5 Sol PCB Long range sensors Motor Assy Solenoid W D 179 348 Input Control Spring Conveyor Belt Shield Photoflag Retrofit Kit Belt 240XL 037 Belt 80XL 037 Belt 90MXL 9 7 Belt 180 S3M 420 PU Belt 100 52M 322 Belt T5 420T 10mm Wide Spring Finger alternative Spring Finger Spring Finger g ooorrrrrrereNEerrerrere D 7 pair Page 3 4 7 Issue 1 Sep 2013 Where Used Main Chassis Conveyor Main Chassis Elect Panel Main Chassis Side Guide Drive Jog Assy Main Chassis Stacking Conveyor Insert Track MainChassis Main Drive Side Guide Drive MainChassis Roller Drive Main Chassis Wheel Drive Insert Track Insert Track T over Wheel T overWheel T overWheel Page 3 4 7 DS 1200 G3 Service Manual In addition to the standard spares list the following list will also be required if a CEM Cutter is fitted Order part number AO3O3A Note These holding spares are in addition to the consumable spares shown previously NTL Part No SC 06014919 SC 08019941 SC 14000494 SC 14001107 SC 14001225 SC 14001279 SC 14001319 SC 14004101 SC 14004915 SC 14009464 SC 14009770 SC 14009771 SC 14009772 SC 14009805 SC 14009912 SC 14017777 SC 15014918 SC 15015070 SC 15016815 SC 15019403 SC 15023039 SC 16016846 SC 21000600 SC 21000985 SC 21007736 SC 21014682 SC 21051134 SC 24007216 SC 240162
16. 647 A 9110958F F5010A 9104438P F5016A 9104444V F5036A 9105640R F5135A 9107674K Drive F5145A 91055935 F5 0168 A 9109500M G1217A 9105605E G1217A 9105605E G1218A 9105606F Description Opto pair long range sensors Motor PCB Assy 5 Sen 5 Sol PCB Long range sensors Motor Assy Solenoid Dual LS SS XH Solenoid W D 179 348 Input Control Spring Conveyor Belt Shield Spindle Ink Roller Red Ink Roller Blue Photoflag Retrofit Kit Belt 240XL 037 Belt 80XL 037 Belt 90MXL 9 7 Belt 180 S3M 420 PU Belt 100 52M 322 Belt T5 420T 10mm Wide Spring Finger alternative Spring Finger Spring Finger g D 2 SS A kA kA kA kA FA FA MUMM AAA kA kb ki kA CO OO OO kA kA Where Used Main Chassis Conveyor Main Chassis Elect Panel Main Chassis Side Guide Drive Ink Marker Jog Assy Main Chassis Stacking Conveyor Ink Marker Ink Marker Ink Marker Insert Track Main Chassis Main Drive Side Guide Drive Main Chassis Roller Drive Main Chassis Wheel Insert Track pailnsert Track T over Wheel T over Wheel T over Wheel Page 3 46 DS 1200 G3 Service Manual A0416A Without ink markers NTLPart No 117 240 179 8780 180 745 180 790 181 079 181 153 BO174A BO192A A0 0647 A F5010A F5016A F5036A F5135A F5145A F5 0168 A G1217A G1217A G1218A SAP Part No 9100130B 9107427C 9107019C 9105270F 9107462P 9107231Y 91055522 9105551Y 9110958F 9104438P 9104444V 9105640R 9107674K 9105
17. 74 SC 24016275 SC 28022112 SC 63005157 SC 63005310 SC 63005313 SC 63005501 SC 63005633 SC 64001042 SC 64009156 SC 64009159 SAP Part No 9105147C 9105148D 9105149E 9105150F 9105151G 9105152H 9105153 9105154K 9105155L 9105156M 9105157N 9105158P 9105159Q 9105160R 91051615 9105162T 9105163U 9105164V 9105165W 9105166X 9105167Y 91051682 9105171C 9105172D 9105173E 9105176H 9105177 9105179L 9105180M 9105181N 9105183Q 9105184R 91051855 91051861 9105187U 9105188V 9105189W 9105190X 9105191Y Description GAS STRUT TRACTOR PICK BALL BEARING 5 16 5 BALL BEARING 8 22 7 BALL BEARING 6 19 6 BALL BEARING 10 30 9 6200RS BALL BEARING 10 26 8 BALL BEARING 17 35 10 6003 ZZ CAM FOLLOWER BALL BEARING 20 42 12 6004 2RS NEEDLE BEARING 10 14 10 DHK 10 10 NEEDLE BEARING 22 30 13 RNA 4903 NEDLE BEARING HK 0810 NEEDLE BEARING 10 17 12 NK 10 12 NEEDLE BEARING 12 16 10 HK 1210 BALL BEARING 17 35 8 16003 2Z TOOTHED BELT 200XL050 DUAL TOOTHED BELT MXL 80094 TOOTHED BELT TRACTOR TOOTHED BELT 120XL050 BELT 128 XL037 O RING OR4075 BRUSH OPENING SPRING BRUSH PRESSURE SPRING BEARING COMPRESSION SPRING TENSION SPRING BLADE PRESSURE SPRING CIRCULAR KNIFE UPPER BLADE 1 6 TUNGSTEN LOWER BLADE SIBONI MOTOR ASSY FUSE 15A SLOW 125V 10x38mm Fuse 10 A slow Fuse 3 15 A slow 5A FUSE FUSE 6 3A SLOW MICROSWITCH FIBER OPTICS PHOTOCELL SICK WT160 N470 KA kk Eh NNNNNR NR RNNOAONN kk kk kk kk ke
18. 756 9105179L 9105181N 9105180M 9107506K Description Tyre Feed Wheel Conv belt MAM 5E 911 x 14 Conv belt MAT 02H 265 x 15 Conv belt MAM 04H 1646 x 15 Conv belt MAT 02H 697 x 15 Tractor Pick Felt Pressure Spring Pressure Spring Circular Knife Lower Blade 320 Upper Blade 1 6 320 Re ground Blade Set Page 3 43 DS 1200 G3 Service Manual Output Processor The following list shows the parts recommended to be held for an Output Processor E1524AA E1525AA E1526AA or E1529AA A full set of the parts can be obtained by ordering part no A0428A 230v 115v NTL Part No 181 153 A2 1014 A F1243A F5005A F5014A F5077A F5124A G1025A Flatbed Feeder SAP Part No 9107231Y 9105234T 9104274T 9104433 9104442T 9104479G 9104504H 9104625 Description SOLENOID W D 179 348 SM GEARBOX ASSEMBLY CAST PULLEY 18XL x 8mm BELT 170XL 037 BELT 100XL 037 BELT 175MXL BELT 100 S2M 300 STS SPRING PRESSURE TS er The following list shows the parts recommended to be held for an E1554AA Flatbed Feeder A full set of the parts can be obtained by ordering part no A0427A 230v 115v NTL Part No 181 132 F5001A F5138A G1201A SAP Part No 9100811L 9104429E 9109482T 9109483U Description CLUTCH W D 179 154 2WXH BELT 130XL 037 BELT 370 DXL TURNOVER SPRING Neree cr Note These holding spares are in addition to the consumable spares shown previously Page 3 44 Issue 1 Sep 2
19. 9N Blue Indicator Light EA 2 182 494 9101032R Switch reed 4 Pin PCB EA 1 A0 0496 A 9104482K Itrack pawl belt kit EA 1 A0 0502 A 9107759Y Shuttle pawl belt kit EA 1 A0286A 9101269N Spares Fold Roller EA 1 A2 1014 A 9105234T Gearbox assy cast EA 1 A2 1196 A 9108386B Encoder Assy Spares EA 1 Page 3 38 DS 1200 G3 Service Manual Page 3 39 Issue 1 Sep 2013 NTLPart No SAP Part No Description Unit Qty A2 1197 A 9108381W Bearing Holder Assy Spares EA 10 A2 1219 A 9109480R Back stop assy DS 1200 EA 1 A2675A 9101562T Roller assy Hi cap Feed EA 1 BO 0207 A 9107762B Pawl Plate 1 EA 6 BO 0216 A 9108387C Guide Spring EA 2 BO 0218 A 9108496R Collate Brush EA 1 BO 0219 A 9108497S Pawl Plate 2 EA 6 BO 0220 A 9108498T Pawl Plate 3 EA 6 BO199A 9105549W Track Overguide Spring 1 EA 1 BO200A 9105548V Track Overguide Spring 2 EA 1 C8 0204 A 9106869W Outfeed Roller Folder EA 4 C8171A 9103537A Roller Hi cap Separator EA 4 E0346A 9103783G Spring preload EA 2 E0574A 9105864Z Rubber Foot EA 4 E0590A 9105229N Wetter Tank EA 2 E1 0155 A 9110970T INA Bearing Needle EA 6 E1054A 9103819U Bearing 12mm roller EA 4 E1061A 9103826B Bearing 8mm roller EA 8 E1078A 9103835L Bearing 8mm x 22mm flanged roller EA 4 E1087A 9103838P Bearing 12mm x 21mm flanged roller EA 4 E1 0155 A 9110970T Bearing needle roller EA 6 E4033A 9104072H Washer waved 8mm ID EA 2 E4051A 91040815 Washer waved 22mm ID EA 6 E4052A 9104082T Washer waved 13mm ID EA 6 E5015A 9
20. A 1200 C6315A 1000 C6394A 1200 C6395A 1200 DOOO9A E1 0155 A 1200 E5105A 1200 F5087A F5101A 1200 F5159A 1200 G5041A G5042A G5048A G1 0269 A 1200 F5138A Hi Lo Cap NTL Part No A2759A A2796A A2797A BO 0202 A C8127A C8171A DOOO9A 1200 DOO50A SAP Part No 9107055Q 9101269N SAP Part No 9101829W 9103397E 9108390F 9108391G 9103593 9110970T 9104150P 9104484M 9104488R 9108392H 91052157 9105610K 9104864H 9108393 9109482T SAP Part No 9101589W 9101595C 9101596D 9108363C 9103509W 9103537A 9105595 9103617 Page 3 43 Issue 1 Sep 2013 On line with CEM Cutter Collator or Folder see also following page Description NTL Part No Outfeed Roller Assy DOOO9A Spares Fold Roller G5052A G5059A Description G5064A Bearing Holder 4 reqd G5067A Ball Carrier SC 08019941 Ball Carrier SC 21008033 SC 21008726 SC 24007216 SC 24016275 SC 24016274 SC 320RG SET Paper Back Support Tyre Feed Wheel 6 5 Needle Bearing 8 read Pin Dowel 3 x 24 4 read Conv Belt 170T T5 Belt STS S2M 220 Collate Pawl Belt Pair Conv belt MAM 5E 1417 x 14 Conv belt MAM 5E 1583 x 14 Conv belt MAM 04H 350 x 15 Collate Spring Belt 370 DXL Description Drive Roller Assy Feed Roller Feed Roller Anti Wedging Brush Feed Roller Hi Grip Separator Transport Tyre Pick up Roller Tyre SAP Part No 9103593 9105612M 9106333N 9108708M 9106456R 9105148D 9105174F 91051
21. CB assy Dual Distribution PCB assy Module no heatsink PCB assy Module with heatsink PCB Assy Daughter A Motor DC Hybrid MTR Wired 179 802 PCB MTR Step 3STK S S Wired MTR Step 3STK D S Wired ni EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA e O e e e re e re Fb h Fi kk Fb Fi Fb Fb ki BeBe Fa Issue 1 Sep 2013 Page 3 37 DS 1200 G3 Service Manual Page 3 38 Issue 1 Sep 2013 NTL Part No SAP Part No Description Unit Qty 181 0840 9108494P Side guide motor assy EA 1 181 0880 91095362 MTR Step 1STK S S Wired EA 1 181 128 91008076 Clutch Lenze 04 EA 1 181 129 9100808H Brake Lenze 04 EA 1 181 130 9100809 Solenoid 25 dia EA 1 181 131 9100810K Solenoid 19 dia EA 1 181 132 9100811L Clutch Lenze 03 EA 1 181 133 9100812M Brake Lenze 03 EA 1 181 134 9100813N Solenoid rotary EA 1 181 138 9100814P Clutch Lenze 03 collator EA 1 182 333 9100973E Switch reed 3 Pin In Line EA 1 182 340 9100978K Emitter chassis mnt 200mm EA 1 182 343 9100981N Emitter chassis mnt 300mm EA 1 182 437 9101007Q Emitter PCB 100mm EA 1 182 439 91010095 Receiver PCB 100mm EA 1 182 440 9101010T Emitter PCB 200mm EA 1 182 441 9101011U Receiver PCB 200mm EA 1 182 442 9101012V Receiver PCB 200mm N A EA 1 182 443 9101013W Emitter PCB 300mm EA 2 182 444 9101014X Receiver PCB 300mm EA 2 182 445 9101015Y Receiver PCB 300mm N A EA 2 182 464 9101023G Harness Power Sharing EA 4 182 487 910102
22. DS 1200 G3 Service Manual Page 3 1 Issue 1 Sep 2013 SECTION 3 SERVICE OPERATIONS Page Page Safety Notes Power Source amp Labels 3 2 3 3 5 Shuttle amp Kicker Belt Replacement 3 17 3 1 Preventative Maintenance Checklist 3 5 3 3 6 Turnover Belt Replacement 3 18 Maintenance General 3 5 3 3 Envelope Conveyor Belt Replacement 3 19 Service 6 Months 7 1 million Inserts 3 5 3 3 8 Handover Belt Replacement 3 20 Reliabilty Information 3 7 3 3 9 Wetter Closer Belt Replacement 3 21 3 2 Module Identification 3 9 3 4 Folder Maintenance 3 22 Feeder Interface 3 9 39 Envelope Opener Beam 3 23 Shuttle Shuttle Bed 3 9 3 6 Remote Control Unit Setup 3 24 Track Cassette 3 9 3 7 Engineering Screen 3 26 Kicker Handover 3 10 Hardware Setup 3 26 Turnover 3 10 Firmware Download 3 28 Envelope Opener Conveyor 3 11 Engineering Diagnostics 3 29 Feeder Folder 3 11 OMR Barcode Reader Setup 3 31 Wetter Closer 3 12 3 8 QX Hawk Reader 3 33 3 3 Drive Conveyor Belt Replacement 3 13 3 9 Recommended Spares 3 38 3 3 1 Track Cassette Belt Replacement 3 13 3 3 2 Folder Drive Belt Replacement 3 13 3 3 3 Feeder Interface Belt Replacement 3 14 3 3 4 Feeder Conveyor Belt Replacement 3 16 Page 3 1 DS 1200 G3 Service Manual CAUTION Prior to carrying out any maintenance procedures on the machine the following safety precautions must be observed Switch the machine OFF by turning the isolator switch on the rear of the insert head cover to the off position
23. ON COUTRE LES D INCENDE REMPLACER PAR UN FUSBLE DE MEME OMINALES IRES TYPE ET DE MEME CA VES N PROTECTION DES DEUX POLES FUSBLE SUR LE NEUTRE HIGH LEAKAGE CURRENT High Leakage Current Label G3357A Earth connection essential before connecting supply Fitted to the outer cover behind the insert NE EE head below the envelope feeder Raccordement la terre indispensable avant le raccordement au r seau Page 3 3 DS 1200 G3 Service Manual Warning and Safety Labels cont Kamp fingers lang holr lossa olothing ond Jewellery elar of moving party Fingar affanea haar lama klaldung katten und ormbandar son bemraglichan teilan fernholan Wartarar be dadas palo paruelos y calgentes aportadan de Ion pors an movimlanta Fereevar Isa delgta chere valemente amplas wt mjau a distance dar Hates on mau ramen conveyor and to diverter below top tray Laser warning label G3363A Fitted on the horizontal sur face close to the OMR Bar code read head on all OMR Barcode units Warning plate G3068A Fitted to the top of opening covers on collator flatbed feeder single O L vertical stacker one of each of two covers hi lo cap feeder Page 3 4 Issue 1 Sep 2013 Page 3 4 DS 1200 G3 Service Manual CAUTION Observe the safety notes on the previous pages before carrying out any maintenance procedures Lethal votages are present when the mchine is still connected to the mains Ensure the mains supply
24. QX Hawk it is a simple case of trial and error to find the best reading angle Page 3 36 DS 1200 G3 Service Manual 3 9 RECOMMENDED SPARES Page 3 37 The following list shows the parts recommended for Service Agents to hold in stock to provide a measure of breakdown cover for the DS 1200 G3 It includes parts most likely to fail in service or be subject to damage In addition to these holding spares consumable spares as described on the following page should also be obtained These would normally be chargeable items to the customer or supplied as part of a service contract A full set of holding spares can be obtained by ordering part number A0 0491 A 230v 115v NTL Part No 135 317 UL 135 410 135 430 167 011 180 675 180 676 180 689 180 692 180 701 180 702 180 709 180 711 180 713 180 714 180 776 180 808 180 811 180 812 180 813 181 049 181 064 181 0820 181 0830 AP Part No 9100332M 9100333N 9100334P 9100366X 9100702X 9100703Y 9100709E 9100711G 9100714K 9100715L 9100718P 9100719Q 9100720R 91007215 9100753A 9107532M 9107507L 9108027C 9108028D 9100778B 9100786K 9109535 9108552Z D ription Fuse On board 10A Fuse 38mm 10A Fuse 38mm 30A SLEEVE H50X25 BLACK PCB assy Stepper PCB assy Control PCB assy disc sensor PCB assy vane sensor PCB assy Hicap Motor PCB assy Wetter PCB assy Interlock PCB assy OMR PCB assy CPU PCB assy overflow Wide Body Index Sensor P
25. Turning the switch does not isolate the PC from mains supply which is left on for ac cess to technical documentation To switch this off also the power cable must be isolated from the incoming supply by switching off at supply source If it is intended to access the mains distribution DIN rail behind the insert head the machine must be isolated from the mains supply Failure to isolate the mains could result in death or injury The DIN rail is protected by an inner safety panel retained along its top edge by 2 screws The panel must always be replaced when maintenance work is completed Before switching the machine back on after completion of maintenance work ensure all external covers are in place and un damaged Replace any covers that are damaged PUT SAFETY FIRST The following electrical information for the incoming mains supply on the 1000 1200 must be noted Mains wiring should not normally need attention and unless there is a specific reason it should not be changed Input Voltage 230v 50 60Hz 10 maximum Power Connector Machine fitted with BS4343 32A IP44 industrial free plug connector con forming to EN60309 1 amp 2 and CEE17 Mating socket required at supply source Notes 1 If for any reason it is required to change away from the supplied plug please note that the replacement device used must have a rated current carrying capability greater than 30A and meet all safety requirements for that coun
26. V 3 30V LAMP CABLE Qty KA M kA ee NNNNNRNNee BONFNFTNNE bh Page 3 48 O D DS 1200 G3 Service Manual Page 3 49 Issue 1 Sep 2013 In addition to the standard spares list the following list will also be required if a Tecnau Cutter is fitted Order part number A0 0680 A 9112066K NTL Part No SAP Part No Description Qty NTL Part No SAP Part No Description Qty ST COMMO145 7110864H BELT 2 ST R 0120 9110901W INPUT MERGER ROLLER GROUP 1 ST COMM0146 9110865 BELT 1 ST R 0122 9110902X UPPER ROLLER GROUP 4 ST COMMO168 7110866K BELT 1 ST R 0151 9110903Y MOTOR WITH 90 CABLES EXIT 1 ST COMM0335 9110867L SPRING compression 2 ST R 0152 91109047 EJECTION GROUP 1 ST COMM0366 9110868M O RING 1 ST R COMM0401 C 9110905A B LESS MOTOR ENCODER 2 ST COMM0394 9110869N GAS SPRING 3 ST R COMM0410 9110906B KEYBOARD DISPLAY 1 ST COMM0405 9110870P FAN 4 ST COMM0406 9110871Q SENSOR 2 ST COMM0407 9110872R CAPACITOR 2 ST COMM0411 9110873S MOTOR DRIVER 5 ST COMM0412 9110874T MOTOR DRIVE 2 ST COMM0415 UL 9110875U MOTHERBD 1 ST COMM0415 UL RS 9110876V MOTHERBD COM CONTR 1 ST COMM0477 9110877W PHOTOCELL 4 ST COMM0495 9110878X MICRO SWITCH 2 ST COMM1124 1 9110879Y BRUSH 1 ST COMM7193 91108807 OMR READING PHOTOCELL 2 ST COMM8056 9110881A PHOTOCELL 1 ST COMM8453 9110882B TRANSFORMER 1 ST COMM8478 9110883C GAS DAMPER 2 ST COMM8572 9110884D MOTOR 4 ST COMM8715 9110885E GAS SPRING 2 ST COMM8756 9110886F BELT 2 ST COMM8758 91108876
27. ar Replace tyres if nec necessary essary 4 Check all paper control springs for damage 3 Check that gas struts support covers and conveyors 5 Clean track cassette solenoids 4 Check and if necessary replace the collate pocket backstop rings Envelope opener SEH 1 Check opener plate for wear Replace if necessary 2 Clean conveyor belts and inspect for damage Replace if nec essary 3 1200 only Using DC Motors in the engineering screens run the envelope side guides at HP1 amp HP2 in and out to check operation and free movement If operation is sluggish then remove the overguide assembly to gain access to and service the side guide assembly Kicker 1 Check pawled belts for wear Replace if necessary 2 Check pawled belt pulleys for wear Replace if necessary 3 Check stepper motor belts for wear Replace if necessary 4 Check tips of insert fingers for wear Replace if necessary Note that for the 1200 the finger tips are independently re placeable Handover 1 Clean pawled belts and check for wear Replace if necessary Wetter closer 1 Clean conveyor belts and rollers 2 Check wetter sponge and roller Replace if necessary Page 3 6 DS 1200 G3 Service Manual 3 1 3 RELIABILITY INFORMATION 1000 series The following reliability information applies to 1000 series See following page for 1200 series figures 1 MCBE Mean Cycles Between Error This is the mailing reliability of the
28. at have not been inspected and refurbished after 40 million cycles Page 3 8 DS 1200 G3 Service Manual 3 2 MODULE IDENTIFICATION The machine is constructed of a number of modules each one being re movable and serviceable as a separate unit Each module has a unique name and these names are used uniformly throughout all documenta tion and software and must also be used if referring to Technical Sup port Department All modules are listed below Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig This section shows the location of each module and identifies its name 1 Ei TE Feeder Interface Shuttle Shuttle Bed Track Cassette Kicker Turnover Handover Envelope Opener Envelope Opener Conveyor Feeder Folder Wetter Closer Page 3 9 Issue 1 Sep 2013 Feeder Interface Shuttle Shuttle Bed Raise shuttle to reveal Track Cassette Page 3 9 DS 1200 G3 Service Manual Page 3 10 Issue 1 Sep 2013 Kicker Feeder See also Fig 7 Envelope Opener Turnover eject part of 4 y er Envel C turnover module be ve 4 Long conveyor is shown can also use short convey Turnover or as with feeder above N Ge a PET Fig 3 Fig 5 See also below See also below Kicker raised m 8 Fe _ iii ne mm SS Ss Handover Envelope Opener Conveyor raise clamshell on envelope opener to reveal Page 3 10 DS 1200 G3 Service Manual Pa
29. be 55 mm above the label parallel to the mounting bracket at an angle of approx 5 deg to avoid direct ME reflection the center of the X pattern needs to be on the center of u DV the label and the center of the X pattern 121mm from the hi cap ee feeder exit sensor See diagrams below Page 3 34 DS 1200 G3 Service Manual When the label is correctly positioned relative to the QX Hawk a static read rate alignment test is required From the Engineer screen go to Reader set up Select the correct unit number Start the read rate test checking the label box is selected This will turn the X pattern ON and perform the read rate test The results are displayed in the status line percentage read and the label data The percentage should be 100 The black screen area will show a graphical readout of the results all peaks should be 100 If the test results in excessively low readings less than 100 the angular alignment of the QX Hawk will need to be adjusted an angle between 5 15 deg is acceptable Observe the position of the X pattern on the label the label should be centrally placed directly under the X pattern The QX Hawk is pre programmed with set values for Shutter speed 1 30 000 FOCUS 55mm Ga
30. cessible settings if necessa Units Output Config name 2D Reading Unit 4 Collator Postage Metering Miscellaneous Collator A4 Mark Reading Please select and modify settings Address Position o e F1 96 0 F2 0 0 F3 105 0 pe Ki ease select item from list H OMR Marks 0 A Barcode Labels Inserter H Simulate OMR ES Simulate Label DL A 2D Data Matrix Quadrus or QX Hawk OCR 2D Barcode Labels Camera System E OMR in cutter OMR Marks Raster Mark Reading 2D Data Matrix Quadrus or QX Hawk Reader Head ID Reader Head 1 OMR Marks Camera Bad Reads Groups 2D Data Matrix HiRes Camera Too M dr OMR at cutter MS9 Maximum Fold Forms Reader Setup Procedure Ensure the 2D label is not obstructed by the conveyor assemblies A2710A amp A2711A Adjust if necessary so the label is correctly positioned on the paper support bracket B7388A away from any metal work The alignment is aided by the load to reader feature activated 1 e nr from the Fine tuning screen Follow the on screen instructions Once the label is positioned correctly on the paper support bracket the S QX Hawk needs to be adjusted Go to the fine tuning screen and turn the reader ON The following are critical to ensure reliable reading of the labels The QX Hawk needs to
31. chine Service Life The machine is designed to have a service life of Machine Life 30M cycles The life of the machine does not mean that it cannot be used beyond this number of cycles The life of the machine is based on the fact that many of the functional mechanical components are designed to last 30 million cycles Subsequently after 30 million cycles the machine must be inspected to determine what components modules need to be re placed to allow the machine to be returned to a serviceable unit Service contracts will not be offered on machines that have not been inspected and refurbished after 30 million cycles Page 3 7 DS 1200 G3 Service Manual 3 1 4 RELIABILITY INFORMATION 1200 series The following reliability information applies to 1200 series See previous page for 1000 series figures 1 MCBE Mean Cycles Between Error This is the mailing reliability of the machine and is based on a job which has been fully set up to run at its best performance for documents speed etc Achievable MCBE better than 1 1500 2 MTBF Mean Time Between Failure Service Call This is the mechanical reliability of the machine between Service Calls and assumes the machine has been properly maintained Failure does not necessarily mean the machine has broken down but that the customer has requested a service call that cannot be overcome by phone support The MTBF is based on a 4 station machine with an IS collate unit an
32. d 3 feeders We also assume that the collate unit is processing an average of 2 sheets per document Estimated MTBF 400 000 3 MTTR Mean Time To Repair Repair times for the 1200 need to be broken into 2 categories a Time to get machine back up and running MTTR 2 hours b Time to repair a module fault away from the machine ma chine already repaired and running This is usually possible due to the modular nature of the machine MTTR 2 hours The worst case here would be for a module to take the maximum time to diagnose and replace followed by the maximum time to repair away Page 3 8 Issue 1 Sep 2013 from the machine In this case the MTTR would be 4 hours It should also be noted that a technician would normally expect to re main on site after a repair has been made to ensure that normal run ning has resumed It is estimated that this is a minimum of 1 hour 4 Machine Service Life The machine is designed to have a service life of Machine Life 40M cycles The life of the machine does not mean that it cannot be used beyond this number of cycles The life of the machine is based on the fact that many of the functional mechanical components are designed to last 40 million cycles Subsequently after 40 million cycles the machine mus tbe inspected to determine what components modules need to be re placed to allow the machine to be returned to a serviceable unit Service contracts will not be offered on machines th
33. e If envelope flaps are not opening properly or the opener is becoming noisy check that the rubber pads are intact and that the setting has not moved Problem envelope flaps may open better by deviating slightly from the factory setting The opener beam can be easily accesssed by opening the envelope opener assembly at the front of the envelope conveyor it is located at the open end on the inside 5 5mm bE al FACTORY SETTING ADJUSTMENT SCREW E PIVOT POINT OPENER BEAM Page 3 22 DS 1200 G3 Service Manual 3 6 REMOTE CONTROL UNIT SETUP INSTRUCTIONS Part Numbers Receiver and Hand held Transmitter 184 6990 The remote control unit on the machine consists of two parts a hand held transmitter and a receiver mounted in the machine in front of the PC The frequency on which they communicate is factory set and should not normally require retuning even if the battery in the hand held TX is renewed Should either part be replaced however or if communication fails for any other reason then re tuning will be required This entails removal of the RX from the machine and establishing the frequency link between TX and RX Remote Control Assy Viper Page 3 23 Issue 1 Sep 2013 To remove the receiver from the 1200 G3 Viper models Open the insert head cover The receiver will be seen inside the machine on the LH side against the end panel Re
34. e bearing housings on both sides of the unit Note that on the LH side the housing and bearing can both be removed On the RH side the drive pin will obstruct the bearing so pull the housing off the bearing After removal of the housing the pin and bearing may also be removed 4 The conveyor may now be worked out of the chassis When it is free slide the old belts off over the ends of the conveyor and fit the new ones Belts should always be replaced as a set Note the direction of rotation when fitting and ensure that the belts are centrally located on the pulleys Lower conveyor belt replacement Replacement of the lower conveyor belts requires removal of both the upper and lower conveyors The procedure for removing the lower con veyor is the same as for the upper conveyor as described above It will also be necessary to remove the top end of the two tension springs at the end of the conveyor take off the nyloc nut on each spring The belts are replaced in similar manner to that described above for the upper conveyor If the feeder drive belt requires replacement proceed as described on the following page Page 3 14 DS 1200 G3 Service Manual 3 3 4 FEEDER CONVEYOR BELT REPLACEMENT To replace the feeder conveyor belts requires removal of the feeder con veyor from the input section of the feeder Proceed as follows Ls Remove the side covers from the feeder unit and also the end undercover from the far end of the con
35. e centre can be trimmed out mechanically by tilting the reader in the plane of paper travel or by adding subtracting the fixed amount measured to each future job Page 3 35 DS 1200 G3 Service Manual Page 3 36 Issue 1 Sep 2013 Shingle Feeder Windowed Envelope Setup If you are fitting a QX Hawk to a shingle feeder or an output divert unit With some additional setup it is possible to read a 2D data matrix label please read the following through a windowed envelope The basic problem with reading the 2d label through a windowed envelope is reflection This can be eliminated by increasing the angle of the 2d reader so that 2D Data Matrix Reader QX Hawk fitted to a Shingle Feeder the label is clearly visible in the QX Hawk field of view FOV And Reading through a Windowed Envelope Introduction This supplement is to be used in conjunction with the 2D DataMatrix Setup document The additional information here is for a shingle feeder and for reading through the window of an envelope Shingle Feeder Installation The basic setup of the QX Hawk is still the same There is a fixed focal length so the reader must be positioned 55 mm from the reading surface All readers fitted to a shingle feeder are bottom mounted with the PCB located behind the lower rear feeder cover Reflected view No reflection from envelope OMR PCB in correct orientation window as the QX Hawk angled steeply As it is not possible to see images from the
36. ft the unit upwards slightly to clear the screw heads in the keyhole slots and then slide it forward on the locating pegs to re move it Belt replacement Slacken the two screws marked B in Fig 20 to release belt tension Remove the old belts and fit the new ones ensuring that the pawls on each belt are aligned Tension the belt and tighten the screws Page 3 19 Issue 1 Sep 2013 Screw B Screw A Screw A EF 5 E Clip 8 Fig 20 Reassemble the handover to the machine replacing the E clips and tightening screws A Reassemble the turnover unit and reconnect the 2 ribbon cables from the turnover and 1 ribbon cable from the handover Refit the underpanel When the machine restarts the belts will automatically position them selves Page 3 19 DS 1200 G3 Service Manual 3 3 9 WETTER CLOSER BELT REPLACEMENT 4 The wetter closer is fitted with 2 conveyor belts and 1 drive belt To re place refer to Fig 21 below and proceed as follows Bearing T rest Top plate T rest Bearing T Conveyor Sensor belts plate
37. ge 3 11 Issue 1 Sep 2013 Closer Feeder rear view see also Fig 5 Note that insert and enve Wetter lope feeders are identical units except for drive pulley and belt Coneyor can be short or long Folder front view Feeder front view Fig 8 Page 3 11 DS 1200 G3 Service Manual 3 3 DRIVE CONVEYOR BELT REPLACEMENT The 1000 1200 has been designed for easy access of most of the drive or conveyor belts on the machine In some cases this entails removal of the relevant module in other cases the belt is replaced in situ 3 3 1 TRACK CASSETTE BELT REPLACEMENT To replace the track cassette belt first remove the track cassette 1 Raise the track interface shuttle and also the track interface bed 2 Remove the overguide by taking out the thumbscrew H Unplug the ribbon cable from the PCB next to the motor Lift the cassette upwards to remove it from the slide posts see Fig 10 below 4 With the cassette now removed from the machine slide the belts from the lower pulleys and remove them from the cassette Fit the new belts Note ensure that the pawls are facing in the right direc tion and that the pawls of both belts are in line Track Interface Shuttle Track Cassette Ribbon cable connector Overguide thumbscrew Fig 10 Track Interface Bed Page 3 12 Issue 1 Sep 2013 5 Refit the cassette to the machine and plug the ribbon cable back into the PCB Refit the overguide The pawls wil
38. he envelope conveyor Unplug the ribbon cable see Fig 19 below and remove the two retaining screws The conveyor conveyor can now be lifted upwards and withdrawn Take care not to damage the 2 solenoids underneath it and note that the external drive belt will come loose as the conveyor is withdrawn Belt replacement As previously stated the external drive belt will be freed as the con veyor is withdrawn The 2 conveyor belts can be slipped off the rollers without any disassembly When replacing the belts note the direction of travel and ensure that the black rubberised side is inwards To replace the internal drive belt remove the conveyor belts and the top plate 6 countersunk screws The belt can now be wound off the pulleys and the new one fitted similarly Envelope Drive belt conveyor Ribbon cable Retaining Screw Retaining screw Page 3 18 Issue 1 Sep 2013 Conveyor replacement Replacement of the conveyor is a reverse of its removal Guide the drive belt onto the pulleys as the conveyor is moved into position and ensure that the tensioner is underneath both runs of the belt Refit the retain ing screws and plug t
39. he feeder now removed the feed interface can be also Removal is the same as for a folder see section 3 3 2 except that no cables have to be disconnected With the unit on a suitable working surface belt replacement can now proceed as described on the following page Page 3 13 DS 1200 G3 Service Manual Drive belt replacement 1 On the RH side slacken the screw behind the tensioner pulley to relieve belt tension see Fig 14 below Turn the unit by hand to wind the belt off Note that the screw is awkward to reach but a standard Allen key should allow slackening The upper pulley may also need to be slackened to allow belt removal replacement 2 Fit the new belt in reverse order to removal and re tighten the tensioner pulley The belt must be tight with no perceptible play O GC RS Upper pulley S Bearing l housings Tensioner pulley ome o 72 NO AE O O Fig 14 u 3 If replacement of the inner drive belt for the feeder is required see the following paragraph Lower conveyor belt replacement Page 3 14 Issue 1 Sep 2013 Upper conveyor belt replacement Replacement of the upper conveyor belts requires removal of the upper conveyor Proceed as follows 1 Remove the drive belt as previously described 2 Remove the pulleys in front of the upper bearing housing see Fig 14 these are retained with a circlip 3 Remove th
40. he ribbon cable back in when the conveyor is in place Page 3 18 DS 1200 G3 Service Manual 3 3 8 HANDOVER BELT REPLACEMENT The handover is located between the turnover and the envelope con veyor assembly and contains 2 conveyor belts and 2 drive belts To replace the belts it will be necessary to remove the turnover and then the handover Turnover removal First lower the angled undercover below the turnover and wetter closer To do this remove the two screws one each side on the inside of the angled edge near the top note that the cover is quite heavy and will hinge down when the screws are removed Remove the ribbon cable from the PCB on the RH side of the turno ver eject motor On the LH side trace the ribbon cable from the PCB through the chassis and leading to the Module PCB on the front elec trical panel Pull out the connector and lead the cable up through the chassis opening Remove the two screws securing the turnover base to the chassis These are located near the front corners of the unit Slide the turnover forward and lift it out of the chassis Caution the turnover is heavy do not attempt to lift it without suitable assistance Handover removal With the turnover removed from the chassis locate the ribbon cable leading from the handover Motor PCB to the Module PCB on the head Disconnect it from the Module PCB Slacken the two screws marked A in Fig 20 opposite and remove the two E clips Li
41. in 40 This should be suitable for most applications when the 2D label is of good quality and on a white background Please read the OCR and 2D DataMatrix specification to ensure your label design is within the acceptable range Page 3 35 Centring the label in the FOV There is no TV image supplied with the QX Hawk so the initial set up will help to manually calibrate the label position in the FOV Setup is as follows L Measure the position from the lead ing edge of the document to the centre of the label Enter the value in the barcode setup screen as the Distance from LE to label centre DLE in our ex ample 174 Start running the job If the job runs correctly then adjust the DLE in increments of 3mm up until you start to get bad reads Re cord the value Issue 1 Sep 2013 Standard BCS Control abe Label machine control m Default Grouping End of Group Good decode reads 3 Security check Hone Data log enabled Last page Distance of LE to Label Centre 174 Checksum Off Data logging characters Start pos 1 Length 2 Now adjust the DLE down until you start to get bad reads Record the value The true setting will be the mid point between the two values If the mid point is greater than the measured value then you should add this same correction to all other jobs similarly if it is lower than the measured value The error between the measured value and the tru
42. ine software update for all units together can be effected by clicking the Send to all units button Caution Always exercise care when using Edit mode as the soft ware will accept any settings that you apply regardless of the actual hardware fitted incorrect settings could result in operat ing errors To return to read only mode click the Edit button so that the brackets are unchecked When all changes are complete click the Exit button to return Page 3 26 Issue 1 Sep 2013 Units Setup Hybrid motors fitted to the machine are bi directional and must be set to either forward or reverse direction This is factory set for new ma chines but if a replacement motor is fitted it must be set for direction INFORMATION Please identify the type of motor fitted to each unit and set as follows McLennan Motor FORWARD MCP 57SW03 003S FORWARD GBM Motor REVERSE Seiectunit Unit 0 Inserter H Motors Click on the Select Unit button and select the required station this will show the hybrid motors fitted to the unit Select the required direction according to the data shown in the Information panel Click the Save button to save the data then the Send button to transmit this to the unit Important H Motors must be set to either forward or reverse not undefined Miscellaneous These features are set as default values by the software upon initial in stallation and should n
43. ing marks run the follow ing Read Rate Test Remove the reader head and scan the following barcodes in sequence Scan this barcode to enable the test reader head should bleep and flash LEDs Scan this barcode to enable symbologies LEDs should flash up and down settling on 100 Scan this barcode to start read rate test LEDs should flash up and down settling on 100 To end the Read Rate Test scan this barcode If the test does not perform as described above repeat it The reader head should should be moved fairly briskly through the barcodes mak ing sure that the outer ends of the red line do not pick up spurious readings from any other distracting marks at the sides Note The test must be performed in the Engineering screen as follows Engineering Diagnostics Reader Setup tab Barcode Start Align Test Now perform the Read Rate Test as described above Page 3 31 DS 1200 G3 Service Manual 3 8 QX HAWK READER 2D DataMatrix Set Up for QX Hawk Installation Instructions Attach the 2D reader mount B2 2169 P to the QX Hawk CCD reader 179 8661 Attach the reader assembly to the vertical head bracket B8616P ensuring the correct orientation see diagram below
44. is completely isolated before removing any machine covers or carrying out any other maintenance operations 3 1 PREVENTATIVE MAINTENANCE CHECK LIST When all items have been carried out worksheet must be signed to confirm 3 1 1 GENERAL 1 Ask how the machine has been working lately and use this information as a guide for checking the machine 2 Askif there has been a change of use e g high production runs or a change of material 3 Check the operator adjustments of the machine and the ma terial being processed 4 Switch on machine and confirm that no errors appear on the display screen 5 If necessary generally instruct the operators again with re gard to their specific problem area Enter the total forms count on the service sheet When all service or repair operations have been carried out the machine must be left with all parts reassembled leaving no risk of injury 3 1 2 SERVICE AT 6 MONTHS OR 1 MILLION INSERTS 1000 or 1 5 MILLION 1200 1 Implement the actions in section 3 1 1 General Remove all machine covers Vacuum clean all modules to remove internal dust Clean all covers Page 3 5 Issue 1 Sep 2013 4 Print and check sensor calibration see Engineering Diagnos tics under section 3 5 then clean all sensors and re check calibration 5 Check envelope and insert side guides for movement stop position and parallelism to chassis 6 Check that steel overguide tapes on shuttles in
45. iso lated at wall Page 3 2 DS 1200 G3 Service Manual Earth Connections The earth wires from incoming mains outgoing mains and the connection to all other fuses terminate at the main earth post This is located at the rear of the insert head and is visible after removing the panel for the mains switch as described on the previous page Earth connection Page 3 3 Issue 1 Sep 2013 Warning and Safety Labels The 1000 1200 is fitted with a number of warning and safety labels which must be in place and undamaged If any are found not to be they must be replaced Labels are identified below geet Rating and Compliance Plates E1532BA Located on inside of hinging top Serial No OAQ 59 61 cover of envelope feeder AE ALL 115 230 V 50 60 Hz HIATT EM neopost NEOPOST TECHNOLOGIES LTD Loughton Essex IG10 3TZ UK Model No E1532BA Serial No OAQ 59 61 NEOPOST TECHNOLOGIES LTD Loughton Essex IG10 3TZ UK Ce a EL o 250v Fuse caution label 2A G3297A CAUTION sewer era or Fitted to the electrical panel behind the PC next to the socket connecting the PC FIRE REPLACE ry WITH SAME TYPE AND RATING OF FUSE VORSICHT WELEN BRAUCCEFAHR SICHERUNCEN NUR GEGEN GLEICHEIN TYP UND STARKE AUSTAUSCHEN PHASEN UND NULLEITERSICHERUNG PRECAUCION PARA EVITAR RIESGO DE INCENDK EMPLEAR SULONENTE FUSIBLES DEL WISWO TIPO Y CAPACIDAD DUS FUSIBLES POSITNO Y NEGATNU ATTENTION POUR NE PAS COMPROMETTRE LA PROTECTI
46. l automatically move to their correct position when the machine is next run 3 3 2 FOLDER DRIVE BELT REPLACEMENT The folder has two drive belts located on the RH side To replace them the folder must first be removed from the 1000 1 Raise the track interface shuttle and also the track interface bed to gain access to the PCB at the front of the folder Remove the data and power cable from the LH end of the PCB 2 Gain access to the rear of the folder by withdrawing the feed de vice Hi Lo Cap Feeder or IS Collator with Hi Lo Cap Feeder 3 Remove the two lower side infill covers from the rear of the folder 2 x Csk Head screws each side This will provide access to the four mounting screws see Fig 11 below u ol g e 2 Jes f y vw of ar AG o I G Fig 11 Mounting screws 4 Slacken the mounting screws it is not necessary to remove them fully Slide the folder back to clear the keyhole slots and lift the folder off the stand Warning The folder is very heavy lifting should not be undertaken without suitable assistance contd Page 3 12 DS 1200 G3 Service Manual 5 Place the folder unit on a suitable bench or stand The two drive belts are visible on the RH side as shown in Fig 12 below To remove the outermost belt slacken
47. le F5096A 1000 9109503Q Kicker Belt pair F5101A 1200 9104488R Timing Belt 220 STS S2M F5103A 9104490T Turnover Transport Belt F5154A 1200 9104511Q Kicker Belt single 3 reqd Page 3 41 Issue 1 Sep 2013 Page 3 41 DS 1200 G3 Service Manual NTL Part No G0128A GO178A G5043A G6144A Track NTL Part No F5078A F5079A 1000 F5 0167 A 1000 F5161A 1200 F5 0167 A 1200 G5048A G5049A Feeder NTL Part No C8106A C8127A DOO38A DOO46A F5000A Flatbed Feeder Part No C8171A DOO38A DOO46A F5000A F5023A SAP Part No 9104596D 9105225 9104860D 9104914K SAP Part No 9104480H 9109341W 9109351G 9109504R 9109351G 9104864H 9104865 SAP Part No 9103503Q 9103509W 9103611C 9103614F 9104428D SAP Part No 9103537A 9103611C 9103614F 9104428D 9104449A Description Turnover Brush Wetter Sponge Envelope Conveyor Belt Turnover Restrictor Belt D ription Belt STS 90 Tooth Shuttle Belt pair Cassette Pawl Belt pair Shuttle Belt pair Cassette Pawl Belt pair Conv belt MAM 04H 350 x 15 Conv belt MAM 04H 454 x 15 D ription Roller Feed Feed Roller Feed Wheel Tyre Silicon Feed Tyre Belt 90XL Description Separator Roller Higrip Feed Wheel Tyre Silicon Feed Tyre Belt 90XL Belt 300XL Page 3 42 Issue 1 Sep 2013 Page 3 42 DS 1200 G3 Service Manual Folder NTL Part No A2 1018 A A0286A Collator NTL Part No BO177
48. machine and is based on a job which has been fully set up to run at its best performance for documents speed etc Achievable MCBE better than 1 1000 2 MTBF Mean Time Between Failure Service Call This is the mechanical reliability of the machine between Service Calls and assumes the machine has been properly maintained Failure does not necessarily mean the machine has broken down but that the customer has requested a service call that cannot be overcome by phone support The MTBF is based on a 4 station machine with an IS collate unit and 3 feeders We also assume that the collate unit is processing an average of 2 sheets per document Estimated MTBF 300 000 3 MTTR Mean Time To Repair Repair times for the 1000 need to be broken into 2 categories a Time to get machine back up and running MTTR 2 hours b Time to repair a module fault away from the machine machine already repaired and running This is usually possible due to the modular nature of the machine MTTR 2 hours The worst case here would be for a module to take the maximum time to diagnose and replace followed by the maximum time to repair away Page 3 7 Issue 1 Sep 2013 from the machine In this case the MTTR would be 4 hours It should also be noted that a technician would normally expect to re main on site after a repair has been made to ensure that normal run ning has resumed It is estimated that this is a minimum of 1 hour 4 Ma
49. move the 3 screws holding the receiver to the support bracket and lift it out on the end of its cable Pairing a Transmitter to a Receiver Each transmitter has a unique identity Each time a transmitter Switch is operated it emits a secure RF signal The Receiver can learn this signal and allocate to any of its outputs The only limitation is that each receiver has a maximum memory for up to 40 pairings these can be from the same or any number of transmit ters Hint the same transmitter may be taught to different receivers to cre ate master keys VIPER S1 VIPER S2 VIPER S4 12 30Vdc Receivers To Learn a New Transmitter switch follow this procedure Any transmitter button can be learnt to one or many of the receiver output relays Each button must be learnt to each relay individually by following this pnocedure 1 Select the receiver output relay to learn to 2 Briefly press the receiver Learn switch S2 once 3 The Learn LED will flash once to indicate output relay 1 is se lected 4 After the LED stops flashing press the Learn switch again to select the next relay channel 5 Repeat step 2 until the required output relay is selected 6 Press the button on the transmitter you want to learn to the relay output 7 The Learn LED will then illuminate press the same transmitter but ton again 8 The Learn LED will then flash to indicate learning is complete Page 3 23 DS 1200 G3 Service Manual
50. nd JST connectors at the front edge Place a rag un der the connector of the fluid pipe press in the latch and separate the connector Lift out the wetter tank The unit can now be lifted out of the machine Take out the 2 sensor plate screws and hang the plate over the top of the front face Take care to avoid straining the sensor wires Remove the T rests and also the screw below in each vertical channel Remove the 4 screws marked A and lift out the top plate unclipping the 2 sensors underneath as it is withdrawn Detach the solenoid spring from the plunger by pulling out the clip Remove the bearing in 4 positions as shown note that the ball bearing is loose in the housing and there is wavy washer inside the front housings only Alternatively leave the bearings in place but open up the circlip on the inside of each bearing and slide it inboard Move the far ends of the conveyor shafts inboard of the chassis sufficiently to allow the belts to be looped off over the ends of the Shafts Fit the new belts in a similar manner Reassemble all parts in reverse order to their removal Page 3 20 DS 1200 G3 Service Manual 3 4 FOLDER MAINTENANCE The folder module consists of five fold rollers and three fold plates al lowing all combinations of folds Fold plates 1 amp 3 are vertical mounted above the rollers fold plate 2 is below pointing downwards A spring loaded blanking beam is fitted to the roller at the o
51. oading and being reported in the right hand window With the mode switched off it will be possible to upgrade each module separately Change params parameters should not normally be changed without consulting Technical Support The defaults should always apply unless there is specific reason otherwise These defaults are Packet numbers 4 Send interval ms 1 Overflow timeout s 10 Page 3 27 DS 1200 G3 Service Manual Page 3 28 Issue 1 Sep 2013 Engineering Diagnostics DC Motors Note Prior to operating Engineer Diagnostics the paper paths Tests the small DC motors Use the buttons to switch the unit on and should be cleared by pressing the Autoend button on the run off screen Remove all stationery from the feed units Stepper Motors Tests the stepper motors Use the buttons to switch the unit on and off gt Raper Sensors Please fill settings our Solenoid DE Motore Stepper Motore Pope Sensore ech Sansare Size isstanen All sensors auto calibrate at the finish of each auto end cycle This mn ensure that any build up of paper dust and toner will not degrade per formance over a period of time Auto calibration can be turned off from Sensor Cal Control in the engineering screen Feeder H Motor Folder H Motor ol Ss E E eed Sep Clutch eed Sep Brake Collator H Motor Diverter H Motor OFF OFF OFF OFF E F F Feed Clutch Feed Brake F Tests the pape
52. old Return EA 2 G1162A 9104703Q Spring Conveyor interface EA 4 G1165A 91047055 Spring Solenoid EA 2 Page 3 40 DS 1200 G3 Service Manual NTL Part No SAP Part No Description Unit Qty G1176A 9104710X Spring Stop EA 2 G5043A 9104860D Belt Envelope Opener Conveyor EA 2 G5048A 9104864H Belt Upper Conveyor EA 6 G5049A 9104865 Belt Lower Conveyor EA 6 G5074A 9107157W Conveyor Belt HAT 5E Feeder PR 1 G5075A 9107284D Conveyor Belt HAT 5E Long Feeder PR 1 G6144A 9104914K Tape Turnover restrictor EA 2 G6 0235 A 91107535 Tape Turnover Restrictor EA 2 Consumable Spares Order these parts as required to suit the units fitted to the machine Quantities will depend upon machine usage and can be calculated for any configuration by contacting IPSS department Items shown are for both 1000 and 1200 except where indicated otherwise Inserter Head NTL Part No SAP Part No Description AO275A 9101264H Envelope Sealing Fluid 10 litres A2634A 1000 9101551G Finger Assy LH A2635A 1000 9101552H Finger Assy RH A2 1198 A 1200 9108388D Finger Tip Kit LH Spares A2 1199 A 1200 9108389E Finger Tip Kit RH Spares C8106A 9103503Q Roller Feed C8132A 9105484D Transport Roller DOOO9A 9103593 Tyre Feed Wheel DOO15A 9103598P Tyre Conveyor Roller D0037A 9103610B Closer Feed Tyre F5025A 9104450B Belt XL 110 Tooth F5078A 9104480H Belt STS 90 Tooth A0 0498 A 9104485N Handover Pawl Belt Kit F5095A 9109502P Turnover Eject Pawl Belt sing
53. ot be altered without consulting IPSS department Page 3 26 DS 1200 G3 Service Manual Firmware Download The machine firmware EPROM program can be updated in this screen using the appropriate file copied to the local computer All station units can then be updated together default or under certain circumstances selected units only Ae shown below the current firmware build data will be displayed and this will be updated when the download is complete Please fill settings Units Current firmware build data File Unit 0 4 2 3 4 5 6 v Unit 0 Inserter Build version Build number Unit Build date v Unit 1 Feeder Unknown Bytes left Bytes se Status v Unit 2 Feeder v Unit 3 Folder v Unit 4 Collator v Unit 5 Feeder v Unit 6 Collator Change params Select all Deselect all Files Iw Broadcast mode Use the Browse button to find the txt file on the local computer and click the Download button The right hand side of the screen will show the selected file and the status of the download Under normal circum stances no messages will appear in the text area but should errors or special conditions occur these will be displayed here Page 3 27 Issue 1 Sep 2013 Broadcast mode this allows insert head and all other modules to be upgraded simultaneously rather than each unit in turn Default is ON and should only be turned OFF if problems are encountered when down l
54. ote Prior to using any of the engineering functions the paper paths should be cleared by pressing the Autoend button on the run screen Remove all stationery from the feed units Page 3 25 DS 1200 G3 Service Manual Editing the settings When in edit mode click the unit that you wish to add or modify and then select the unit type and unit equipments select the option of Dis able Separators only if you wish to continue to run the machine if a separator has malfunctioned the station would otherwise prevent the machine functioning Also select the unit type modifier of Blank Station if this has been fitted in place of an operable unit Click the Save button to update the INI file the file that retains the information that the machine is to work from Now click the Send to unit x button to synchronise the software with the updated INI file It is important that both these functions are carried out or else either the INI file or the machine software will not be updated Synchronisation can be confirmed by clicking the View machine button to reveal the settings in the lower columns and then the View INI but ton to reveal the INI file settings they should be the same The former indicates the settings actually received by the machine software the latter indicates the settings in the INI file but not necessarily sent to the machine If anumber of units have been modified added in one session the ma ch
55. oward ul em mm Paper direction Cable towards Last mark under Reverse mer Hi Cap Feeder reader head Paper direction lt wll Cable towards First mark under Reverse m Collator reader head Paper direction _ ei Gate Mark Cable towards Last mark under Foward ll Paper direction l HH Gate Mark As set in OMR Screen in setup see Operating Instructions page 25 mm mn LOT OU Collator reader head IL N mm mM Repeat the tests and if results are still poor slacken the lock screws and move the head closer to or further from the paper as necessary until the test results are good If read problems are still occurring carry out a read rate test as decribed opposite OMR Calibration This need only be carried out for OMR readers Load the calibration sheet into the unit s feed hopper and press OMR Calibration on the Run screen The sheet will feed to the divert bin or to the track with a screen message to advise of successful calibration Page 3 31 Issue 1 Sep 2013 Read Rate Test If the reader head is having problems read
56. pening of each fold plate this being automatically operated when required by a pusher on the backstop of the fold plate The fold plates are motor driven and no manual settings are required The two lower fold rollers are spring load ed the tension of which can be adjusted Roller spring adjustment The folder springs on the two lower rollers are adjustable by means of eccentric spring posts The springs are factory set to maximum tension which should suit the great majority of applications but if lightweight forms are being processed min 70 gsm rippling of the form will be prevented by reducing spring tension as described below 1 Unlatch fold plates 1 3 and hinge forward 2 Slacken the screws behind the adjustable spring posts see Fig 22 below and turn the posts to reduce spring tension Each post on each side must be turned by a similar amount Ensure the screws are fully re tightened 3 Test run the machine to determine improvement and adjust further if required the springs should be as tight as possible while main taining a smoothly folded form Spring posts Page 3 21 Issue 1 Sep 2013 Fold roller replacement The folder is a complex structure with the roller shaft locked to the bearings with adhesive Further positive locking is provided by 2 ring nuts on the ends of each shaft these also being locked in place by adhesive It is designed for considerable longevity and fold roller should not normally need
57. r Select the Percent Read Test button and then Start align test to test the head alignment The black screen area will show a graphical readout of the results all peaks should be above or close to the red line The status line below the screen will indicate the percentage success Run the test for at least 10 seconds then click the Stop align test button Now click the Decodes Sec Test button and observe the same proce dure as for the Percent Read Test If either test results in excessively low readings the angular alignment of the read head or its closeness to the paper may require adjustment Observe the position of the red beam through the perspex cover over the read head the side to side postion should be centrally placed on the marks or barcode If necessary slacken the lock screws and adjust the head to suit it will be necessary to close the cover after each small adjustment as the beam switches off when the cover is raised Note OMR Reading Depending on paper orientation and whether the Gate mark is the first or last mark past the head the head must be physically positioned according to the chart on the following page To change posi tion slacken the lock screws and position the head on the other side of the sliding bracket See following page Page 3 30 DS 1200 G3 Service Manual Head Cable towards Hi Cap Feeder Gate Mark First mark under reader head Position Gate Mark Direction F
58. r sensors Condition of sensor is indicated as shown below Note that this is a read only display and is for information only Particularly check the clear and blocked voltages sensors outside the ranges shown should be replaced 7 eed Exit Clutch Feed Exit Brake Collate HP1 Clutch Collate HP1 Brake E Collate HP2 Clutch E Collate HP2 Brake HEED HGH Es Divert Clutch Percentage of effort to calibrate Clear C 0 5 to 0 9v sensor eg high figure probably Blocked 4 5 to 4 9v means calibrating when blocked E Ku Divert Brake Unit 6 Collator Yellow means value has changed since Opener Enty 2 8V 3mA 12 lc 0 7V last calibrated Er N H Motors Tests the hybrid motors Use the buttons to switch the unit on and off Motors can be tested at all speeds up to 9 Envelope BS Clock u Solenoids Tests the solenoids and clutches Use the buttons to switch the unit on Threshold voltage switch Current drawn to achieve threshold and off Light refers to the blue indicator Clutches and brakes will be point from blocked to clear Depends upon distance between heard to click when switched though this will be faint it is suggested sensor halves and ambient light that the feeder motor is switched on first then the clutches and brakes will activate their shafts Page 3 28 DS 1200 G3 Service Manual Mech
59. replacement However if they do or they become damaged it is not considered feasible to strip the assembly and it must be replaced as a whole Folder module A0286A is available as a spares assembly which comprises the core folder assembly It does not in clude fold plates outer side plates amp posts pulleys belts circuit board drive motor fold plate motors microswitch ke Remove the folder as described in section 3 3 2 2 Remove the outer side plates posts and stretcher bars Note one of the posts requires removal of the PCB chassis see step 5 3 Remove fold plate 2 by taking out the 4 screws behind leaving the blocks in place From the inside remove the 2 screws securing the fold plate motor lift this out and disconnect the cable see Fig 23 below Also remove the angled chassis plate behind the fold plate Fold plate motor Screws Fold plate mounting block 4 Tilt fold plates 1 3 forward and remove the fold plate motors from inside the chassis as with fold plate 2 Take out the screw at each end of the pivot shaft and lift out the fold plate assembly Page 3 21 DS 1200 G3 Service Manual PCB Posts 10 11 Disconnect the cables to the circuit board Pull of the daughter board remove the metal plate over the board and then the securing screws posts securing the board Do not disconnect cables from the daugh terboard Remove the 3 chassis screws and lift out of the chassis See Fig 24 below
60. rrect settings Changing readers from Quadras to QX Hawk Go to the hardware set up screen In the Extra settings tab select Reader on channel 1 to QX Hawk Page 3 33 Issue 1 Sep 2013 Label Setup Procedure Setup a new label for the 2D data matrix following the standard procedure defining the number of characters the control method the position of the control characters in the label the data logging parameters etc The distance from the leading edge to the label center must be filled in for your particular document Measure in mm the distance from the leading edge LE of the document to the center of the 2D data matrix label This dimension is required to get the label in the FOV of the QX Hawk Configuration Setup Procedure This is the procedure for the first time setup of the reader All subsequent configurations will work without needing to find the optimum settings for the label Setup a new configuration we have called it 2D Reading select the mark reading as 2D Data Matrix and the reader as reader 1 Set the bad reads to stop in the collate This will cause any bad read document to stop at collate HP1 or collate HP2 When the set up diagnostics is complete set the bad read destination back to divert 1 or 2 or however you require it for this configuration Page 3 33 DS 1200 G3 Service Manual Page 3 34 Issue 1 Sep 2013 Configuration 2D Reading se edit available and ac
61. sert track and kicker are not bent twisted or damaged Replace any that are 7 Check that gas struts properly support all opening covers envelope opener clamshell and collate unit conveyors where fitted Replace if any are defective or sinking 8 If gears on insert feeder run noisily lubricate sparingly with Molyslip MBG moly bentone grease Raise cover at front end of feeder to access In addition to the above carry out the following in individual modules Note rubber feed wheels rollers must be cleaned using a clean lint free cloth dampened with water Do not use any other cleaning agents Feeders insert and envelope 1 Clean conveyor belts and inspect for damage Replace if nec essary 2 Clean feed wheels and inspect for wear Replace tyres if nec essary Folders 1 Clean fold rollers and inspect for wear Replace if necessary 2 Clean output wheels and inspect for wear Replace tyres if necessary Hi Lo capacity feeders 1 Clean feed wheels and inspect for wear Replace if necessary Page 3 5 DS 1200 G3 Service Manual Page 3 6 Issue 1 Sep 2013 Track 3 Clean wetter reservoir Replace tank if necessary 1 Check pawled belts for tension and wear Replace if neces Collator SE 1 Clean conveyor belts and inspect for damage Replace if nec Check pawled belt pulleys for wear Replace if necessary essary Check stepper motor belts for tension and wear Replace if 2 Clean feed wheels and inspect for we
62. sting and added feed units below 2 Setting direction of motors and drive ratio E Downloads of updated firmware 4 Diagnostic testing of motors solenoids and sensors DL a To enter Engineering mode click the Engineering button in the setup ege Geng i Se Sg screen This will display the dialog box shown below to allow the re Fe Be Gegen zum quired function to be selected Folder Flat bed Divert type Standard Divert d kon Omr reader Online type None WS J Barcode Label reader E Ee mos weg Franker jam sensor Franker interface Hardware setu Ink marker Units setup Fold OMR Firmware download Feed OMR Diagnostics Disable separators Unit ID setup s External devices Network devices Blank station Dual Inkmarker Y Divert Valipost JV interface ensor Cal Control Send to all units Reader setup Plug and Play Make changes by selecting the Edit tab at the top and then the unit you wish to configure Select the appropriate settings in the other columns The View tab provides an overview of the settings Units column This shows the units currently defined on the machine when a unit is physically added to a station it will not be recognised by the software until it has been defined in edit mode this is described later Click the arrows at the top of the column to add or subtract units Clicking on any unit already defined will show its settings N
63. try Page 3 2 Issue 1 Sep 2013 2 Changing the supplied plug negates any responsibility of the Company for the safety integrity of the machine 3 Changing the supplied plug must be carried out by a qualified electri cian 4 If 2 x Hi Cap Folders a Hi Cap and a Lo Cap Folder or an OMR Bar code Folder with any other unit are located next to each other on the Same track pair it is necessary to order and fit an additional power sup ply kit 184 156 to ensure correct operation Incoming Mains Connections The mains is connected to the isolator switch located at the rear of the insert head above the wetter fluid bottle To gain access remove the outer cover then the plate holding the switch Observe the polarity of the incoming mains cables the brown cable line connects to L1 the blue cable neutral connects to N note that colours may vary depend ing on locality The cables exiting at the bottom of the switch are con nected to the DIN rail fuses as described below DIN rail fuses The mains supply from the mains switch see above is connected to the main 30A fuses located on a DIN rail with all other fuses at the rear of the insert head below the envelope feeder To gain access remove the outer cover below the envelope feeder then the cover panel inside The main fuses are protected by a further cover as shown below Protective cover over fuses and mains cables Warning High voltage PC always live unless
64. veyor Disconnect the con veyor motor from the module board under the feeder head Remove the retaining screws 1 x Skt Cap head from each side as shown in Fig 15 below Lift the conveyor upwards and rear wards to remove it from the input end of the feeder Retaining screw EN AN gt Fig 15 Place the conveyor upside down on a suitable working surface taking care not to damage the side guides Referring to Fig 16 opposite 1 Remove the tensioner assemblies from the bulkhead plate 2 screws and washers each remove the screws for the bulkead in ner plate roller shaft and tiebars Also remove the outer screws on the motor plate posts and the screws at the other end of the motor plate but leave the motor plate attached to the bukhead Leave the tensioners on the belts at this stage Remove the drive belt bulhead plate with motor plate attached inner plate roller shaft and tiebars S Page 3 15 Issue 1 Sep 2013 Tensioner assemblies Bulkhead plate Motor Roller plate shaft Tiebar Inner plate Conveyor belts Tiebar Fig 16 Viewed from underside of conveyor Slide the belts out from underneath the backstop on the top sur face and slip them over the sides of the conveyor Fit the new belts in a similar manner Replace the bulkhead plate roller shaft inner plate and tiebars Reassemble the tensioners in reverse order to their removal and adjust them so that free

SECTION 3 - SERVICE OPERATIONS

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