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7 • Service Menu & Troubleshooting

1. 4 1 4 3 Removing Sheet Feeder Separator Roller 4 Pad 4 2 4 4 Removing Carriage Assembly 4 3 4 5 Removal of Lower Collation Roller 4 4 4 6 Removal of Upper Insert Drive Rollers 4 5 4 7 Fold Roller Removal Replacement 4 5 4 6 4 8 Dismantling Insert Feeder 01380 51330 Only 4 7 4 9 Dismantling Insert Feeder 01425 513500 4 8 4 10 Removal of Top Assembly esses 4 9 4 11 Removal of Envelope Feed Rollers and Separator Pad 01380 51330 4 10 SDT335A MMI Service Manual amp Parts List Contents 4 12 Removing Envelope Feeder 01425 513500 Only 4 11 4 13 Removing Envelope Feed Rollers 4 Separator Pad 01425 513500 ONIY 4 11 4 14 Removal of Flapper Assembly and Blade 4 12 4 15 Removal of the Transport Pivot Plate amp Insertion Roller 4 13 4 16 Removal of Sealer Rollers 4 13 4 17 Removing the Inverter Motor Assembly 4 1
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3. ated 1 5 5013333 DI380 DI425 SI3300 S13500 Service Manual 10 14 10 Diagrams 10 13 SCHEMATIC DISPLAY PSU 8 YILNI 2 0 1 AvC cL ung JOJO 2855 AS ueiS JOJO 1455 AS 2 L 01 6 8 ON Uld 91601 AS AS AO AO Ave Ave 10 15 SDT333A DI380 DI425 SI3300 S13500 Service Manual
4. Pitney Bowes SECAP 01380 01425 Series Document Inserting Systems Includes Secap models 513300 513500 Service Manual FORM SDT333A 4 06 Model feature availability varies by country Contact your machine supplier for more information This guide covers all models and features Inclusion within this guide does not guarantee availability of a particular model or feature within your country The title copyright and all other proprietary rights in this document are vested in Pitney Bowes Limited and no part of it may be reproduced in any form without the written permission of Pitney Bowes Limited The document is for the exclusive use of the person to whom it is issued its contents are confidential and must not be disclosed to any third party or used for any purpose other than in the proper conduct of Pitney Bowes Limited s business and it must be returned to Pitney Bowes Limited immediately upon the person ceasing to be associated with Pitney Bowes Limited Pitney Bowes Limited 2006 Contents 1 Introduction 1 1 also M 1 1 1 2 Equipment 1 1 1 3 Related Publications Une od Ema Seded 1 1 1 2 1 4 6 c P 1 1 1 5 Safety SUMMAN 13 1 6 1 4 2 Specifications 2 1 Material Spec
5. Fold Plate 2 Sensor OP 4 Transport Pivot Plate Unblocked Blocked Sensor OP5 SOFTWARE TRIGGER 3 Theory of Operation Envelope Motor M9 ON Envelope Sensor 51 ON Lead Edge Sensor 52 ON C Delay Insertion Solenoid 1 ON Y Hold Down Solenoid L2 ON OFF Y Shoe Horn Solenoid L3 ON OFF Y Finger Solenoid L4 ON Sealer Solenoid L5 ON Insertion Solenoid L 1 Off Y Moistener Sensor S3 Software Counter Shoe Horn Solenoid L3 OFF 54 Mechanical Item Counter Flow Diagram Accumulation Sheet Feeder 1 Mode 5013333 DI380 DI425 SI3300 S13500 Service Manual 3 Theory of Operation 3 9 DOUBLE DETECT SENSORS only adjustable in the service parameters screen and are not operator selectable This is to allow the engineer to choose different detection reference points to suit the customer s application Sheet Feeder 1 and Sheet Feeder 2 have three positions available LEAD MIDDLE and TRAIL The Insert feeder has only the one option LEAD The Detection sensors work on an LED emmiting through the thickness of the paper onto a Opto detector The double detection takes 14 reference poin
6. EXIT i 3 9 3 Theory of Operation 3 6 3 10 TWO SHEET FEEDERS PLUS AN INSERT MODE When the start button is pressed The insert pre feeder motor M3 is energized and feeds a single insert past the Double Document Detection DDD3 sensor If a double is detected the machine will stop and the double insert symbol will be indicated on the control panel If no double is detected motor M4 will energies and will feed the insert into to the insert collation area and stop The sheet feeder motor M1 is triggered by the insert passing through the Double Document Detection DDD3 feeds the sheet over the Double Document Detector DDD1 The Double Document Detector DDD1 triggers sheet feeder motor M2 to feed the sheet through the Double Document Detector 0002 both sheets stop after a counted delay in the collation nip This will result in the sheets being slightly over driven At the same time the envelope motor M9 is energized An envelope is fed through the separator pad and roller When the lead edge of the envelope moves forward to the envelope sensor S1 the software sends the signal to energize the collation motor M5 The transported envelope will stop in the insertion area at a predetermined time according to the size of envelope programmed within the job setup The insertion solenoid L1 energizes followed by the hold down solenoid L2 and finally by the shoe horn solenoid L3 When the sheet ente
7. If the difference between the measurements is greater than 0 5mm 0 020 undo the three fixing screws on the upper Q Station and adjust the alignment until it is within parallel limits Exit the Set Parameters menu 5013333 DI380 DI425 SI3300 S13500 Service Manual 5 Adjustments 5 122 Station Calibration Q Station Alignment must be completed before carrying out this adjustment Refer to the illustration below 2 Enter the Set Parameters menu on the display Choose Q Station Calibration Finger Stop A value of 130mm z2 will be displayed Place an envelope into the Q Station ensuring that the lead edge of the envelope is touching the Finger Stops Using a ruler measure accurately the distance from the envelope lead edge to the insertion shaft on either side of the Finger Stops marked A and B in the illustration and record the measurements These measurements should be within x0 5mm of each other if the Alignment adjustment has previously been carried out correctly Enter the measured distance using the keys Press Start to save the setting then exit from Diagnostics Deck Plate Envelope Lead Edge Insertion Shaft Deck Plate Distance must equal distance B 0 5 Q Station Adjustments 5013333 DI380 DI425 SI3300 S13500 Service Manual 5 9 5 Adjustments 5 12 3 Q Station Height This adjustment allows the height of the Q Station to be adjusted to aid in the insertion of
8. 01380 513300 ONLY 1 10 Remove the lower left hand envelope feeder area covers from the front and rear side of the machine Unclip the cover from the envelope flap deflector and unclip the out of paper sensor Remove the following from the rear side Envelope feed motor held in place by 3 screws and white gear from separator shaft Envelope Feed Motor E clip from the pre feed shaft Remove the E clip washer and gear on the E clip Washer front side of the pre feed shaft and Gear Move separator assembly towards the front of the machine Be A Remove pin pulley and belt from the front end of the separator shaft Note orientation do the F 1 Vut E MN n ti 1 wmm 1327 sy Pin and Pulley uw Remove all bearings from the frame and remove the separator pre feed assembly Remove the rollers and bearing from one side only To remove the separator pad undo the 2 screws on the separator plate Reassemble in reverse order ensuring that the separator roller is central to the separator pad 5013333 DI380 DI425 SI3300 S13500 Service Manual 4 Removal amp Replacement 4 12 REMOVING ENVELOPE FEEDER 01425 513500 ONLY 1 2 Remove envelope feeder covers Disconnect wiring for Upper and Lower Limit Sensors IL13 amp IL14 at th
9. 5013333 DI380 DI425 SI3300 S13500 Service Manual 10 Diagrams 10 4 PCBLAYOUT 24 P25 P27 P28 SDT333A 01380 01425 513300 513500 Service Manual 10 7 10 Diagrams 10 5 DRIVE BELT ROUTING Rear View Front View 10 8 5013333 DI380 DI425 SI3300 S13500 Service Manual 10 Diagrams SCHEMATIC INSERTION MOISTENER EXIT AREAS 10 6 112 1 36 301 1 36 ie EN 17 GION31OS NOLLH3SNI 2 015 LL 0L 62d INOHJ a OL d 714290094 V L E 1 5 75 ASNAS Lixai E EJ 3008 6 Hd Vds ANI L 27 105 2 980 3 NOH Sat ANI 1 v1 ES 4 LEd LEN T ANII Tg 4 1 9 0 or 6 OLIN SOIN eed 65 Cn YHANALSION Ng _ 222 LE cr 2 26 7 EE 5 E cS ASNAS 3903 21 6 H V deca H35NIJ 0 zd S ASNAS zed rdO 3SN3S 3WOH jHANALSION
10. This sequence is shown in flow chart form on the following page 50173333 DI380 DI425 SI3300 S13500 Service Manual 3 Theory of Operation Insert Pre Feed Envelope Motor M9 Motor M3 ON Y Insert Envelope Sensor S1 DDD 3 Sensor ON Lead Edge Sensor S2 ON Insert Collation Motor M4 Insertion Solenoid L1 Hold Down Solenoid 12 ON Transport Pivot Plate Unblocked Blocked Sensor OP5 0 Shoe Horn Solenoid L3 ON Finger Solenoid L4 ON Sealer Solenoid L5 4 Down Solenoid L2 OFF Insertion Solenoid L1 OFF SOFTWARE TRIGGER gt Shoe Horn Solenoid OFF PAPER PATH Moistener Sensor Software Counter S3 Exit Sensor Mechanical Item Counter S4 Flow Diagram Insert Feeder Mode SDT333A DI380 DI425 SI3300 S13500 Service Manual 3 5 3 Theory of Operation 3 4 3 6 TWO SHEET FEEDER MODE When the start button is pressed the sheet feeder motor M1 is switched on This feeds a sheet over the Double Document Detector 0001 sensor This triggers sheet feeder motor M2 to feed a sheet up to the Double Document Detector DDD2 Both sheets stop after a counted delay in the collation nip This results in the sheets being slightly over driven At the same time the envelope motor M9 is switched on and an envelope is fed through the separator pad and roller When the lead edge of the envelope moves forw
11. Sheet Feeder 1 Interlock Sheet Feeder 2 Interlock OP2 P19 Wires still present but not in use Envelope Interlock 4 5 6 5 Yellow 5 high 5 high Pivot Transport Plate White OV low 5V high P36 3 4 5 Black low Half Fold On P46 10 11 12 Half Fold Off OP8 P16 Reflective Sensors Wires Blocked Unblocked Location Sheet Feeder 1 Paper Empty 009 P20 19 20 21 Yellow 5V high 5V high White 5 high 20 21 22 Black low low SDT333A 01380 01425 513300 513500 Service Manual 10 3 10 Diagrams 10 4 Magnetic Reed Switches PCB Location Wires Blocked Unblocked Location Black OV low low Envelope Feed 51 18 19 White OV low high Lead Lead Edge Moistener ater 12 oo tat et a Yellow 5V high low White OV low low Water 5813 1516 Solenoids PCB PIN Location Location 24 24V high Insert Envelope Drive Roller low 24V high Blue 24V 24V high Hold Down low 24V high White 24V 24V high Shoe Horn White low 24V high lo Orange 24V 24V high Finger Solenoid Grey OV low 24V high Yellow 24V 24V high Moistener Yellow OV low 24V high Motors DC PIN Location Sheet Feeder 1 Orange 24V high 24V h Sheet Feeder 2 Insert Col
12. and pad Replace motor M1 Encoder 7 15 7 Service Menu amp Troubleshooting Error Codes Operator Check List Service Diagnostic Connector and Replacement and fault Logic Test Parts E57 Sheet Feeder 2 fail to feed E58 Insert Feeder Fail to feed E59 Envelope feeder failed to feed E60 Stream feed sheet feeder 1 16 Adjust the sheet feeder side guides alignment by a 1 4 turn Check that the material is not stuck together Aerate stack and reload Adjust the insert feeder side guides alignment by a 1 4 turn Check the position of the wedge and adjust if necessary Adjust the separator lever and the stone shield Adjust the envelope feeder side guides alignment by a 1 2 turn Poor envelope quality Check the position of the wedge and adjust if necessary Check that the material is not stuck together Aerate stack and reload Check alignment of the side guides Check the daily mail switch is properly positioned Press trial piece to re calibrate the machine Check the condition of the separator roller and pad Test the condition of the Sheet feeder motor M2 Test Encoder Check the material is within spec Check the condition of the separator and pre feed rollers Test insert motor M3 Test Encoder Check the material is within spec Height of pad Check the condition of the separator and pre feed rollers Test out of paper sensor OP12 Check the mechanic
13. washer and blue handle behind the AC hand crank door 6 Disconnect ribbon connector from logic board before removing control panel 7 the moistener cover and release the 2 springs on both sides of the machine and pull out cover It may be necessary to unclip the Q station 8 Disconnect all connectors including port the logic board P C B 1 Remove the 2 screws that holds the logic board backing plate Tilt and lift logic board and backing plate away from machine 2 Reassemble in reverse order 4 2 REMOVAL OF JAM ACCESS PLATE Follow instruction for cover removal in section 4 1 Disconnect Double Document Detector sensor on jam access plate 5013333 DI380 DI425 SI3300 S13500 Service Manual 4 1 4 Removal amp Replacement 4 3 REMOVING SHEETFEEDER SEPARATOR ROLLER amp PAD 1 Follow instruction for cover 4 removal section 4 1 2 Disconnect the following _ 2 WAV connectors on or near the motor bracket assembly P19A P19C P19D P20A P20B P20D and P20E 3 Remove 3 screws from the sheet feeder motor bracket and carefully remove bracket Take care not to lose bearings 4 the rear side remove E clip that holds the bearing in place Slide the bearing inwards and remove E clip washer spring and clutched separator roller 5 The separator pad can be unclipped and replaced at this point Note All the old glue must be removed before
14. Bracket to both side frames 2 Adjust the bracket until a gap of 6mm is achieved between the Separator Pad and Separator Roller A 6mm Allen Key may be used to check the height 3 the Separator Bracket screws Separator Rollers 6mm Allen Key Separator Pad Envelope Separator Pad Height Adjustment DI380 SI3300 5 2 5013333 DI380 DI425 SI3300 S13500 Service Manual 5 Adjustments 5 5 ENVELOPE SEPARATOR PAD HEIGHT 01425 513500 ONLY 1 Loosen the Envelope Separator Pad Adjustment screw A 2 Adjust the bracket until a gap of 6mm is achieved between the Separator Pad and Separator Roller A 6mm Allen Key may be used to check the height 3 the Separator Pad Adjustment screw Separator Rollers Separator Pad Envelope Separator Pad Height Adjustment DI425 S13500 5013333 DI380 DI425 SI3300 S13500 Service Manual 5 3 5 Adjustments 5 6 INSERTION FLIPPER ACTUATION HEIGHT HOLD DOWN SOLENOID ADJUSTMENT 1 Loosen the Hold Down Solenoid mounting screws A slightly 2 Depress the plunger of the hold down solenoid L2 so that the hold down fingers pivot the flippers Move the hold down solenoid in its slots until the flippers raise to a height of 7mm above the deck measured from the points shown in the diagram 3 Fully tighten the solenoid fixing screws Hold Down Fingers REST POSITION Ed ACTUATED POSITION Solenoid Plunger Hold Down Finger Mounting Solenoid F
15. Manual 6 7 6 6 4 6 5 6 6 6 7 6 8 6 8 BASIC OMR Basic OMR enables you to collate multi page documents that vary between one and five sheets 10 sheets with Single fold and certain paper weights It allows you to vary the number of pages per envelope in a run from envelope to another through the use of OMR marks based on the document information in the customer s database Basic OMR does not ensure mailpiece integrity since there is minimal error checking It should not be used for sensitive documents such as invoices The machine will fold each OMR sheet separately and insert it into an envelope starting with the last sheet of the set and adding each folded sheet in turn until the address sheet has been inserted The machine will then eject the envelope after sealing if selected When using Double C or Z folds up to five sheets from one sheet feeder may be inserted into a single envelope with or without a supplementary sheet and or an insert When using Single fold up to 10 sheet can inserted into a single envelope A supplementary sheet or insert counts as 1 of these sheets BENCHMARK This is a mandatory mark within the code and it will be the first mark scanned by the machine it will appear on every sheet within the set SAFETY This mark improves the integrity of the mailing and as it is the second mark scanned the machine will calculate the distance between the marks Once this is done the machine will th
16. Maximum Insert size 230mm Width 152mm Length Paper Weights 75 Minimum non folded cut sheet 180g m Maximum Single Sheet 60 Minimum folded material And Inserts of up to a maximum compressed thickness of 2mm Pre folded or single panel Inserts should be fed from the Insert Feeder Double Document Detector Material range 60g m Minimum 120g m Maximum Feed tray capacity 01380 513300 Up to a maximum of 100 Inserts 1425 513500 Up to a maximum of 300 Inserts Sealer The machine can seal up to a maximum of 1200 envelopes between refills Stacker The envelope Stacker can accommodate up to 150 filled envelopes Dependent on size and contents of the envelope Material Requirements For best performance use only materials approved by Pitney Bowes Materials should be good quality and properly stored Recommended storage conditions 18 C 65 F to 25 C 77 F 40 to 60 relative humidity 2 2 SDT333A DI380 DI425 SI3300 S13500 Service Manual Envelope Feeder Minimum envelope size Maximum envelope size Envelope weights Envelope tray capacity End Clearance Depth Clearance 2 Specifications 88mm Depth 220mm Width DEPTH 164mm Depth 242mm Width VEU 65g m Minimum 100g m Maximum 01380 513300 Up to a maximum of 100 90g m envelopes 01425 513500 Up to a maximum of 300 90g m envelopes End clearance between the Insert and envelope is a minimum of 6mm at each side i
17. Test moistener cover interlock S9 Test chain of interlocks 59 510 56 55 57 511 58 Test station end stop Test Q station motor M10 Test encoder Check the Q station lead screw for binding Test water sensor S13 Check for 5v LED on PCB main logic P24 pins 8 9 P14 pins 4 5 6 P29 pins 10 11 12 13 17 pins 10 11 12 13 P20 pins 19 106 117 10 P14 pins 7 8 9 10 P36 pins 10 11 12 13 P36 pins 15 16 17 18 P37 pins 1 2 P35 pins 4 5 6 P35 pins 15 16 Sensor 512 Sensor OP15 Interlock S6 Interlock S7 Interlock S5 Interlock S8 Interlock S10 Interlock S9 Interlocks S5 S6 S7 S8 S9 510 511 Motor 0 Sensor 513 Replace 5013333 DI380 DI425 SI3300 S13500 Service Manual E44 Feeder 1 separator switch error E46 Feeder 1 manual feed time out E50 Envelope not flapped E53 Half fold not set E54 Envelope lead sensor blocked E55 AC motor Error E56 Sheet feeder 1 fail to feed Check the daily mail switch is properly positioned Check job set up Adjust the sheet feeder side guides alignment by a 1 4 turn Check correct orientation of the envelope Check flapper unit shut properly Remove fold plate 1 check for jammed material Check display for jam symbol Press clear deck button and check stacker for left over material Visually check flapper unit for jammed material Turn the machine off and on Call service Check
18. cover doors are closed Check the daily mail switch is properly positioned Adjust the sheet feeder side guides alignment by a 1 4 turn Check that the material is not sticking together Aerate stack and reload 7 Service Menu amp Troubleshooting Error Codes Operator Check List Service Diagnostic Connector Replacement and fault Logic Test Parts Visually check that the daily mail lever is not broken or cracked Test manual feed OP3 Test out of paper sensor OP9 Check for binds on the flapper blade Check for damage or wear on flapper blade Check bearing position Check for bind on the lead Screw Test half motor M8 Test encoder Test home position sensor OP13 Test half fold sensor OP8 and OP7 Test sensor S2 Check for bind on bearings Check and adjust belt tension Test chain of interlocks 59 510 56 55 57 511 58 Check the condition of the separator roller and pad Test the condition of the Sheet feeder motor M1 Test Encoder 5013333 DI380 DI425 SI3300 S13500 Service Manual P23 pins 1 2 3 P20 pins 19 20 21 P16 pins 1 2 P16 pins 3 4 5 OP13 P29 pins 6 7 8 OP8 P16 pins 10 11 12 OP7 P16 pins 6 7 8 P35 pins 11 12 P21 pins 1 2 P20 pins 4 5 6 Replace OP3 Replace OP9 Replace flapper blade Replace M8 Encoder Replace sensors OP7 Replace 8 or OP13 Replace sensor 92 Interlocks S5 S6 S7 58 59 510 511 Replace the separator roller
19. different thickness of collation and to prevent overdrive of the envelope during the insertion process 1 Loosen the two Q Station height adjustment screws 2 Adjust the height from the deck to the top surface of the Q Station near the pivot spindle to a dimension of 30mm This is its nominal position 3 adjustment screws Note Ensure that both sides are of equal height Adjust height to 30mm check both sides a 4 SS S eee 7 Anc P Q Station Height Adjustment 5 10 5013333 DI380 DI425 SI3300 S13500 Service Manual 5 13 5 Adjustments INSERT FEEDER ADJUSTMENTS Carry out Insert Feeder adjustments in the following order 5 13 1 Separator Roller Alignment Ensure the Separator Rollers are adjusted side to side so that they are centralised with the cut outs of the Separator Stone Centralise rollers with cut outs on stone The Separator Rollers can be adjusted after loosening the allen screw A located close to the Thumbwheel Alignment Allen Screw 5 13 2 Separator Roller Height 1 Remove the Insert Feeder Top Cover 4 screws 2 Move the Detent setting to the middle position 5 setting position 5 ioe 6 0 0 a ties Middle Position DI380 S13300 01425 513500 Detent Se
20. last insert Check internal RS232 cable to PCB Check sensor is working on VPS 5013333 DI380 DI425 SI3300 S13500 Service Manual 7 Service Menu amp Troubleshooting Error Codes Operator Check List Service Diagnostic Connector and Replacement and fault Logic Test Parts E115 VPS Nearly Full E116 VPS Cam Error E117 VPS Entry Jam E118 VPS Undocked E119 MMI Throttle Active E120 MMI Throttle Timeout E123 VPS Docked E124 MMI Disconnected E125 Remove Material from MMI 7 20 Remove from the stacker then press start Pull VPS to un docked position Remove all mail and check for obstructions Dock VPS press reset button on VPS Press start Pull VPS to un docked position Remove any material from VPS entry area then re dock VPS Press start Remove VPS to un docked position Remove any material from VPS entry area Press clear deck Re dock VPS Power on Power off Reference to E120 If there are 4 mail pieces on the mailing deck refer to franking machine Is divert lever set to MMI position correct Move VPS to un docked position Remove any material from VPS entry area Press clear deck Re dock VPS Press start and see if this re installs the MMI Check 85232 cable Check DIN connector between inserter and mialing machine Power off Power on Press clear deck and re try running job Stop inserting and franking machine and wind inserting machin
21. of 8mm in width preferably 10mm A solid black line is preferred but if the mark is printed using hyphens it must be at least two hyphens wide with no more than 0 8mm separation between the hyphens The marks should be black ink on a light background Scan Marks should NOT be positioned within 3mm of the left or right hand sides of the form No text should be positioned within 3mm of the left or right sides of the form Ensure that there is no heavy print on the reverse of the form immediately behind the Scan Marks FEED DIRECTION FOR TOP SCANNING Clear zone 20mm 100mm min 1 100mm min Vertically Center Group within Bracket Rear of SDT 316 Section 7 4 3 of this document shows how to Calibrate the Sensitivity of OMR Sensors SDT3233A DI380 DI425 SI3300 S13500 Service Manual OMR 6 Front of SDT 316 OMR Sensor Manual Sensitivity Setup TOP TRAY lt st START action here gt This point must be 75mm 5mm from the top of the page 2nd START action here BOTTOM TRAY 1st START action here gt This point must be 75mm 5mm from the top of the page gt 2nd START action here gt Form SDT316 RevA 5 02 O Pitney Bowes Limited 2002 Printed in the UK 6 13 6 6 18 6 14 PROCEDURE FOR MANUALLY SETTING THE SENSITIVITY THE SENSORS Introduction It is not normally necessary to change the sensiti
22. on the front side Remove 2 springs from sheet feeder 2 separator pad plate on the front and rear Half Fold Deflector amp sides Sensor Connectors gt Remove pivot screws holding the separator pad plate and then remove the plate from the machine Remove pivot screws holding the half fold motor bracket assembly from both front and rear side frames Gently ease the motor bracket assembly out of the machine Remove all E clips pin and gear from the lower collation shaft Remove bearings from both front and rear side frames Note Take care of wavy washer removed with the bearing on rear side Withdraw shaft from machine Reassemble in reverse order ensuring none of the cables are trapped or touching any of the shafts 5013333 DI380 DI425 SI3300 S13500 Service Manual 4 6 4 7 Follow instruction for cover removal in section 4 1 Remove insert feeder assembly Remove the insert feeder motor bracket held by 3 screws Remove the E clips white gear and pin from behind the insert feeder motors brackets Remove the E clips white gear and pin from the lower shaft Undo the cable tie that limits the movement of the upper insert plate Remove the screws from both the front and rear sides of the upper insert plate 4 Removal amp Replacement REMOVAL OF UPPER INSERT DRIVE ROLLERS Remove both insert drive rollers and replace the bobbins and lower shaft with th
23. pivot plate moves backwards and returns the flag to its home position This operation triggers the software to energize the finger solenoid L4 lifting the fingers and lifting the brush of the sealer by energizing solenoid L5 The document is then driven from the insertion area into the sealer area The next document is fed when the lead edge of the document pushes the moistener sensor 53 forward the software will increment by a count of 1 for the EIU The document then enters the inverter area and finally exits into the stacker The exit sensor S4 will increment the mechanical counter located behind the manual advance knob door by 1 This sequence is shown in flow chart form on the following page 50173333 DI380 DI425 SI3300 S13500 Service Manual First cycle does not stop at the collation motor SOFTWARE TRIGGER gt PAPER PATH gt Flow Diagram The Fold Only Mode SDT333A DI380 DI425 SI3300 S13500 Service Manual Theory of Operation Sheet Feeder Motor M1 Y Sheet Feeder DDD 1 Sensor Collation Motor M5 Fold Plate 2 Sensor OP14 Transport Pivot Plate Unblocked Blocked Sensor OP5 Finger Solenoid L4 ON Sealer Solenoid L5 ON Moistener Sensor Software Counter S3 Exit Sensor Machanical Item Counter S4 3 13 3 Theory of Operation 3 8 3 14 ACCUMULATION FROM MAIN SHEET FEEDER After a trial piece has been processed
24. 0 01425 513300 513500 Service Manual 6 5 6 6 6 To change from Normal Offset to Swiss Offset simply enter service parameters and scroll through until OMR Offset Feeder 2 is displayed This value should be 115 for Normal Offset and 165 for Swiss Offset Any other values entered here are not supported and may cause scanning issues NOTE Select Feed cannot be used when using Offset or Swiss Offset this is due to the late scanning of the code making it too late to collate the supplementary sheet or nest the insert with in the sheet Group 2 OMR still can be used for AutoBatch The minimum paper weight when using Offset or Swiss Offset is 80gsm SDT3233A DI380 DI425 SI3300 S13500 Service Manual 6 3 OMR 6 MARK GROUPING Each OMR code begins with two fixed marks at the end nearest to the sensor Benchmark and Safety mark These are followed by one two or three groups of marks where each group comprises three data marks followed by a fixed mark Each data mark is present or absent as required to reflect the desired function Each code must end with a Retiming Mark Basic OMR mode uses only Group 1 Enhanced OMR mode uses Group 1 plus Group 2 and or Group 3 as needed for a particular job 6 3 1 C Fold and Double Fold jobs Marks must be placed in the upper left corner of the sheet The marks must be printed in the top to bottom order The Benchmark being the mark close
25. 22 pins 1 2 P20 pins 12 13 14 Motor M5 Encoder OP13 P19 pins Sensor OP13 6 7 8 OP14 P17 pins OP14 6 7 8 22 pins 1 2 20 5 12 13 14 Motor M5 Encoder Check LED s on main logic PCB Main PCB Sensor OP1 P20 pins 1 2 3 P19 pins 4 5 6 Sensor OP2 7 13 7 Service Menu amp Troubleshooting Error Codes Operator Check List Service Diagnostic Connector and Replacement and fault Logic Test Parts E32 Insert feeder removed E33 Envelope feeder removed E34 fold plate 1 removed E35 fold plate 2 removed E36 Collation cover open E37 Envelope flapper cover open E38 Inverter door open E39 Moistener cover open E40 Multiple covers doors open E41 Finger stops not set E42 Low water E43 EPROM error 14 Remove and refit the insert feeder tray Remove and refit the envelope feeder Remove and refit the fold plate 1 Remove and refit the fold plate 2 Close collation cover Close flapper cover firmly down Close inverter door Close moistener cover Check all covers doors are closed Check for any material in the insertion area Add water to the reservoir Switch the machine off on If the error is still there call service Test insert feeder sensor 12 Test envelope feeder interlock OP15 Test fold plate 1 interlock S6 Test fold plate 2 interlock o7 Test cover interlock S5 Test flapper interlock S8 Test inverter door interlock 10
26. 25 Operating Guide SDC656 DI425 Operating Guide SDC657 01425 Operating Guide SDC658 DI425 Operating Guide SDC659 01425 Operating Guide SDC660 DI425 Operating Guide SDC661 DI425 Operating Guide SDC662 DI425 Operating Guide SDC663 DI425 Operating Guide SDC1078 DI425 Operating Guide SDC664 DI425 Operating Guide SDC731 DI425 Operating Guide SDC1070 513300 Operating Guide SDC1071 513300 Operating Guide SDC1072 513300 Operating Guide SDC1073 513300 Operating Guide SDC1074 513300 Operating Guide SDC1075 513300 Operating Guide SDC1076 513300 Operating Guide SDC1077 513300 Operating Guide 50132333 1380 01425 513300 513500 Service Manual English German Italian Dutch Norwegian Finnish owedish Danish Hungarian Portuguese Spanish French Pitney Bowes Branded French Secap Groupe PB Branded Polish Czech English German Italian Dutch Norwegian Finnish owedish Danish Hungarian Portuguese Spanish French Pitney Bowes Branded French Secap Groupe PB Branded Polish Czech Italian Dutch English Danish French German Spanish German Hefter Branded 1 1 1 Introduction 1 4 1 5 1 2 SDC1079 513300 Operating Guide Italian SDC1080 513300 Operating Guide Dutch SDC1081 513300 Operating Guide English SDC1082 513300 Operating Guide Danish SDC1083 513300 Operating Guide French SDC1084 513300 Operating Guide German SDC1085 513300 Operating Guide Spanish SDC1086 513300 Operatin
27. 3 DI380 DI425 SI3300 S13500 Service Manual 3 Theory of Operation Envelope Motor M9 ON Sheet Feeder Sheet Feeder Motor M1 Motor M2 M Sheet Feeder Sheet Feeder DDD 1 Sensor DDD 2 Sensor Envelope Sensor S1 ON Lead Edge Sensor S2 ON Collation Motor M5 i i di Fold Plate 2 Sensor OP14 Insertion Solenoid L1 Hold Down Solenoid 12 ON Shoe Horn Solenoid L3 ON Transport Pivot Plate Unblocked Blocked Sensor OP5 Finger Solenoid 4 Sealer Solenoid L5 Hold Down Solenoid L2 OFF Insertion Solenoid L1 OFF SOFTWARE TRIGGER si Shoe Horn Solenoid L3 OFF PAPER PATH c Z Moistener Sensor Software Counter S3 Exit Sensor Mechanical Item Counter S4 EXIT Flow Diagram Two Sheet Feeder Mode SDT333A DI380 DI425 SI3300 S13500 Service Manual 3 7 3 Theory of Operation 3 5 3 8 SINGLE SHEET FEEDER PLUS INSERT MODE When the start button is pressed two motors control the transport of the insert The insert pre feeder motor M3 is energized and feeds a single insert past the Double Document Detection DDD3 sensor If a double is detected the machine will stop and the double insert symbol will be indicated on the control panel If no double is detected the insert will continue to the insert collation area and stop The sheet feeder motor M1 triggered by the insert passing through the Double Docume
28. 4 4 18 Removal of the Conveyor Transport Belts and Rollers 4 14 4 15 4 19 Removing Lower Flapper Rollers 4 15 4 16 4 20 Removal of the Lower Envelope Drive Roller 4 16 4 21 Removal of the Power Supply Unit and AC Motor 4 17 SECTION 5 Adjustments 5 1 Envelope Feed Tray Guides 01380 51330 Only 5 1 5 2 Envelope Feeder Offset Adjustment 01425 513500 Only 5 1 5 3 Envelope Separator Pad Side to Side Adjustment 5 2 5 4 Envelope Separator Pad Height DI380 813300 Only 0 2 5 5 Envelope Separator Pad Height 01425 513500 Only aaannaannnnannn 5 3 5 6 Insertion Flipper Actuation Height Hold Down Solenoid Adjustment 5 4 5 Insertion Hold Down Finger Rest Position 5 5 5 8 Transport Pivot Plate Float 5 5 5 9 Transport Pivot Plate Setting 5 6 5 10 Fold Plates 1 and 2 04 4 221 5 7 5 11 Nesting Constant C 5 8 5 12 Q Station Adjustments 5 8 5 10 5 12 1 Alignment 5 8 5 12 2 Q Station Calibration 5 9 5 12 3 Q Station Height 5 10 5 13 Insert Feeder Adj
29. 425 SI3300 S13500 Service Manual 3 Theory of Operation 3 10 AC MOTOR The machines are fitted with a capacitor start motor which is driven using two solid state relays SSR s Use of a motor start capacitor means the machine can only be started once every 17 seconds on average hence the fitting of the hand crank to assist in the retrieval of jammed material In addition there is a mechanical relay which is used as a safety interlock The mechanical relay is powered from start up If a fault is detected in the A C circuit the relay is de energized until the power is recycled There are also a set of micro switches for use in jam clearance which will remove power from the relay To run the motor the motor start SSR1 and motor run SSR2 are energized together The motor start SSR will stay energized for 500ms or until the motor gets up to speed whichever is shorter If the motor has not attained speed after 500ms both SSR s will shut down and a fault will occur 5013333 DI380 DI425 SI3300 S13500 Service Manual 3 17 3 Theory of Operation 3 18 50173333 DI380 DI425 SI3300 S13500 Service Manual 4 Removal amp Replacement 4 1 REMOVING COVERS AND P C B Covers 1 Disconnect power from the machine before attempting to remove the covers 2 Remove all trays feeders and both fold plates 3 Remove all the metal and black plastic screws and inserts 4 Remove all covers except moistener cover 5 Remove the screw
30. 5 14 SKEW ADJUSTMENT Skew adjustment has been incorporated into the machine to enable a badly skewed document outside skew tolerance of 1 6mm to be folded squarely To set the skew adjustment to central position the following steps should be carried out 1 Loosen the fixing screw Inserta 5mm dowel pin into the centralising hole Tighten the fixing screw Collation Roller Bearing Skew Adjustment To reduce the output skew from a machine the following steps should be followed 1 2 5 14 Loosen the fixing screw Run the machine and observe the skew output Use a large flat bladed screwdriver in the adjustment vee and twist either left or right This will shift one side of the collation roller enabling you to correct the paper skew Once the output skew has been reduced to an acceptable level retighten the fixing screw 5013333 DI380 DI425 SI3300 S13500 Service Manual 5 Adjustments 5 15 FLAPPER ADJUSTMENT 1 Remove the flapper assembly cover four screws Im Em ON 5 Cover locating screws Flapper Assembly Cover 2 Loosen the adjustment plate screws 2 each side DO E a y 2 REMOVE Adjustment Plate screws 3 Place 0 5 to 0 8mm spacers 5 to 8 strips of 80g m paper on AS Rotate 91 6 8 top of the 2nd and 4th arching 8 Tighten screws rollers Bum Tighten screws 4 Close the flapper assembly the
31. 6 542 7 02 Lr L___ 8 mi _ LS 3SN3S 80384 AN3 6 8L az __ 85 V1 55500 H3ddV13 C 2 1146 T CoE 8 6 Br V orld 9140 Wl AVHL ANS geld E LLS MNVHO OV 24444444411 2 EE V OV T 5013333 DI380 DI425 SI3300 S13500 Service Manual 10 12 10 Diagrams 10 10 SCHEMATIC P40 ENVELOPE PLATFORM CONNECTOR 01425 513500 Envelope Sensor 200 7010 Envelope Platform Down Sensor 382323 Envelope Platform Up Sensor 382323 Platform pushbutton N C Polarising Key N C N C N C 10 11 SCHEMATIC P41 ENVELOPE PLATFORM MOTOR CONNECTOR 01425 513500 Platform Stepper Motor NX00418 M20 PB 261 2919 Molex 43020 0401 Qty 1 PB 085 1070 Molex 43031 0001 Qty 4 5013333 DI380 DI425 SI3300 S13500 Service Manual 10 13 10 Diagrams 10 12 SCHEMATIC INSERT FEEDER FIN HOLOW NOLLVTIOO 1H3SNI 1140 ALdW3 AVHL J I aved E 2 D lH M20 1H31NI LJ SW HOLOW E M L83SNI 7 9 1 8 m nos 1935
32. 7 7 7 34 Test Solenoids 7 8 SDT335A MMI Service Manual amp Parts List Contents 7 35 Test A C Motor 7 8 1230 Run Test Cycle 7 8 7 Test Display 7 8 7 3 8 Test Clutch Motor 7 8 7 320 Test Sensors 7 8 723210 Test Service Counter 7 8 7 3 11 Test Interlock Relay 7 8 7 22 Test DDD Calibration 7 8 7 5 19 Select Board Type 1 9 7 3 14 Test Memory 7 9 7 4 Troubleshooting Charts 1 9 7 4 1 General Information 7 9 7 4 2 Double Detect 7 9 7 5 GANS 7 10 7 21 8 Preventive Maintenance 8 1 General ueniet TM 8 1 8 2 The 100k Service 8 1 8 3 The 200k Service 8 2 SECTION 9 Installation 9 1 Unpack and e 9 1 9 2 Operator Training 9 2 9 3 SU pervisor Training 9 2 10 Diagrams 10 1 mier gp dct 10 1 10 2 Component Locations nde quota duis 10 2 10 3 Switches Sensors Motors Solenoids Test Levels 10 3 10 6 10 4 PCE 10 7 10 5 Dive Belt Roung s edid ia mx ERU RUE 10 8 10 6 Schematic Insertion Moistener Exit Areas 10 9 10 7 Schematic Sheet Feeders Collat
33. 99 9 V RI 7 01 0 E ELS SNIS VSEd E uva dO 31V 1d 1 5 V 9 HV319 os 6 _ 10 9 5013333 DI380 DI425 SI3300 S13500 Service Manual SHEET FEEDERS COLLATION MOTOR 10 Diagrams 10 7 SIN HOLOW NOILVTIOO L HOLOW 245 81 0 40 ALdIN3 AVL 2 6 Pie 0 Jr Q35150 18 240 S 0 1 N En 1 9 4 LL 0 130 235 74242 2 4 2 OL TE 640 135 le 2 8 1330018 0 i 2 HY310 S cds Z 9614 D ss V I NOLLVTIOO M 245 a 1 1 11 9 0 INOHJ a 2 Mro S LL 6Zd OL En 5 0 11 9618 Nado 1 m NOILVTIOO _________ 24S 0 Ee i sl B TE V6ld G 1aaHsl 90 1535 6 6
34. I380 DI425 SI3300 S13500 Service Manual n Sheet Feeder Sheet Feeder Motor M2 OP10 Motor M1 OP9 rues ees FEN AN Y 5 Sheet Feeder Sheet Feeder DDD 2 Sensor j DDD 1 Sensor 4 Collation Motor M5 Fold Plate 2 Sensor OP14 Transport Pivot Plate Unblocked Blocked Sensor OP5 SOFTWARE TRIGGER sli PAPER PATH Flow Diagram Single Sheet Feeder Mode 5013333 DI380 DI425 SI3300 S13500 Service Manual 3 Theory of Operation Envelope Motor M9 ON Envelope Sensor S1 ON Lead Edge Sensor S2 ON Insertion Solenoid L1 Hold Down Solenoid L2 ON Shoe Horn Solenoid L3 ON Finger Solenoid L4 ON Sealer Solenoid L5 Hold Down Solenoid L2 OFF Insertion Solenoid L1 OFF Shoe Horn Solenoid L3 OFF didt Moistener Sensor Software Counter S3 Exit Sensor Mechanical Item Counter S4 EXIT i 3 3 3 Theory of Operation 3 3 3 4 INSERT FEEDER MODE When the start button is pressed two motors control the transport of the insert The insert pre feeder motor M3 is energized and feeds a single insert past the Double Document Detection DDD3 sensor If a double is detected the machine will stop and the double insert symbol will be indicated on the control panel If no double is detected the insert will continue to the insert collation area and stop At the s
35. Insert feeder paper too short E16 Feeder 1 Double feed E17 Feeder 2 Double feed E18 Insert Double feed and check for any material Check job set up Adjust the side guides Press the trial piece to re calibrate Check job set up Adjust the side guides Press the trial piece to re calibrate Check job set up Adjust the side guides Press the trial piece to re calibrate Check the paper is aerated Adjust the side guides Press the trial piece to re calibrate Check for any dark areas on the document Check the paper is aerated Adjust the side guides Press the trial piece to re calibrate Check for any dark areas on the document Check the paper is aerated Adjust the side guides Press the trial piece to re calibrate Check for any dark areas on the document Check orientation of the document 51 Visually check the separator pad and roller Visually check the separator pad and roller Visually check the separator pad roller and pre feed roller Visually check the separator pad and roller Check DDD sensor levels Change the position of the DDD position Top Middle Bottom Visually check the separator pad and roller Check DDD sensor levels Change the position of the DDD position Top Middle Bottom Visually check the separator pad and roller Check DDD sensor levels 5013333 DI380 DI425 SI3300 S13500 Service Manual 51 Clean Replace the separa
36. Remove 4 screws from the front and rear sides and remove roller NC ha __ Release Belt Roll the machine back making sure the D Tension water is removed from the sealer tank b 8 5 Pulleys B Pin amp Bearing Remove base plate 5013333 DI380 DI425 SI3300 S13500 Service Manual 4 15 4 Removal amp Replacement 12 Disconnect power supply cable 4 13 Remove 2 screws from power supply top and bottom on right side of Power Supply Unit and pivot the unit to gain access to the roller 14 Remove the roller and plate from the machine 15 Reassemble in reverse order Ensure the cable for the Power Supply Unit is not trapped when refitting 4 20 REMOVAL OF THE LOWER ENVELOPE DRIVE ROLLER 1 Follow instruction for cover and PCB removal in section 4 1 2 Remove and plastic linkage from the rear end of the shaft 3 Remove all E clips linkage pin spring and plastic bearing on the front side 4 the machine back making sure the water is removed from the sealer tank 5 Remove base plate and withdraw shaft 6 Reassemble in reverse order 4 16 5013333 DI380 DI425 SI3300 S13500 Service Manual 4 Removal amp Replacement 4 21 REMOVAL OF THE POWER SUPPLY UNIT AND AC MOTOR 1 2 10 11 12 13 Follow instructions for the removing all covers only in section 4 1 steps 1 6 Undo the port connector from the logi
37. UIDES 01380 513300 ONLY 1 Wind Leadscrew so that side guides are at the middle of the tray 2 Loosen the Knurled Locking Nut and adjust the Bias Adjustment Nut until the guides of equal distance from the central raised tray area 3 the Locking Nut Wave spring washer Bias adjustment Leadscrew nut Locking nut Envelope Feed Tray Guide Adjustment 5 2 ENVELOPE FEEDER OFFSET ADJUSTMENT 01425 513500 ONLY This adjustment enables the envelope to feed biased to the left or right as it travels through the machine This will help with the insertion of some materials especially when using envelopes with inside seams 1 Set side guides to the width of the envelope to be used 2 Loosenthe Envelope Offset Adjustment screw A 3 Movesideguidestorequired position 4 Tighten Envelope Offset Adjustment screw 5 Cycle the machine with sheets inserts and check position of envelope in insertion area Envelope Feeder Offset Adjustment 5013333 DI380 DI425 SI3300 S13500 Service Manual 5 1 5 Adjustments 5 3 ENVELOPE SEPARATOR PAD SIDE SIDE ADJUSTMENT 1 Loosen the two screws holding the Separator Pad 2 Adjust the Separator Pad front to back so that it is centralised to the Separator Roller Separator Rollers Separator Pad Envelope Separator Pad Adjustment 5 4 ENVELOPE SEPARATOR PAD HEIGHT 01380 513300 ONLY 1 Loosen the screws which hold the Separator
38. able enhanced OMR functionality 7 2 17 Basic Wetter Constant This sets the timing of the sealer brush to contact the envelope flap Lower numbers contact the envelope sealer earlier Higher numbers make the sealer brush contact the envelope later 1425 513500 5 DI380 SI3300 110 5013333 DI380 DI425 SI3300 S13500 Service Manual 7 3 7 Service Menu amp Troubleshooting 7 2 18 OMR Acc Wetter Constant This function performs the same function as Basic Wetter Constant but when OMR Acc is used it contacts the envelope earlier to allow for sealing of thicker packages DI425 813500 5 e DI380 S13300 55 7 2 19 T1 Clutch Release Time This adjustmentis basically a stop position for the envelope depth European flap depths are typically deeper than standard or US envelopes For deeper envelope flaps increase the number Standard setting for USA envelopes is 112 Standard setting for European envelopes is 122 7 2 20 T2 Envelope Hold Time Default setting is 0 This adjustment is basically the Envelope Hold time Set to a slightly higher figure if the glue needs longer to break down e 1425 513500 0 Safe Seal Clutch 1 Without Safe Seal Clutch 1380 513300 0 Safe Seal Clutch 1 Without Safe Seal Clutch 7 2 21 T3 Table Offset Default setting is 0 Do not change this setting The software measures the number of pages collation in order to determine whether or not the envelope should be held in the se
39. al OMR 6 Standard OMR Positions 54mm min 96mm Feed Direction for Top Scanning max C and Double Fold min Clear Zone 115mm 20mm x 115mm min Vertically centre group within area indicated Z and Single Fold Clear Zone 20mm x 100mm min 20mm min Feed Direction for Bottom Scanning marks should be positioned as follows Fold and Double Fold 7 Fold and Single Fold TOP SCANNING TOP LEFT CORNER BOTTOM SCANNING BOTTOM RIGHT CORNER Diagram NOT to scale 50132333 1380 01425 513300 513500 Service Manual 6 3 6 Offset OMR Positions Feed Direction for Top Scanning C and Double Fold Feed Direction for Bottom Scanning Z and Single Fold marks should be positioned as follows C Fold and Double Fold TOP SCANNING LEFT MARGIN Z Fold and Single Fold BOTTOM SCANNING RIGHT MARGIN Diagram NOT to scale 6 4 SDT3233A DI380 DI425 SI3300 S13500 Service Manual OMR 6 Swiss Offset OMR Positions Feed Direction for Top Scanning C and Double Fold Feed Direction for Bottom Scanning Z and Single Fold marks should be positioned as follows Fold and Double Fold TOP SCANNING LEFT MARGIN Z Fold and Single Fold BOTTOM SCANNING RIGHT MARGIN Diagram NOT to scale 50132333 138
40. al operation of the pre feed roller clutch Test envelope feed motor M9 Test encoder Check the material is within spec Check the condition of the separator pad and roller 5013333 DI380 DI425 SI3300 S13500 Service Manual Replace the separator roller and pad P18 pins 1 2 Replace motor M2 P19 pins 1 2 3 Encoder Replace separator pad Replace the pre feed rollers and or separator roller Replace insert motor M3 27 pins 1 2 P24 pins 1 2 3 Encoder Separator roller and pad P14 pins 20 21 22 Replace sensor 12 Pre feed roller clutch P15 pins 1 2 Envelope feed motor M9 P14 pins Encoder 14 15 16 Separator roller and pad E61 Stream feed sheet feeder 2 E62 Stream feed on insert feeder E63 Multiple tray empty E64 AC handcrank cover open E65 Invalid Interrupt E66 Stack overflow No display Check that the material is not sticking together Aerate stack and reload Check alignment of the side guides Press trial piece to re calibrate the machine Check that the material is not sticking together Aerate stack and reload Check separation setting Check alignment of the side guides Press trial piece to re calibrate Check and Reload all trays and feeders Close AC handcrank Turn the machine off on Remove all material from the paper path Turn the machine off and on Is the machine turned on at the mains Check the fuse i
41. al Cover Interlock Closed e Moistener Cover Interlock Closed Water Level Full Empty 5013333 DI380 DI425 SI3300 S13500 Service Manual 7 Service Menu amp Troubleshooting 7 3 2 Test UART This is a Loop Back Test for the RS232 serial port EIU Use only 7 3 3 Test D C Motors Start Motor To test the motor press START START will switch the motor On and Off The motor will automatically switch off after 7 seconds Sheet Feeder 1 Sheet Feeder 2 e Collation Insert Pref Insert Drv Envelope Start Motor Count amp Stop For this test enter the number of encoder counts and press START Note When testing lead screws be careful not to over drive the gear to the end as this may damage the assembly Sheet Feeder 1 Sheet Feeder 2 Collation Insert Pref Insert Drv Envelope Station Fold Plate 1 Fold Plate 2 Inverter Half Fold Env Platform 01425 513500 ONLY Reverse Motor Count amp Stop Q Station Fold Plate 1 Fold Plate 2 e Inverter Env Platform DI425 813500 ONLY Envelope DI425 813500 ONLY Half Fold Test End Stops e Q Station Fold Plate 1 Fold Plate 2 Inverter e Env Platform 01425 513500 ONLY Half Fold 5013333 DI380 DI425 SI3300 S13500 Service Manual 7 7 7 Service Menu amp Troubleshooting 7 3 4 Test Solenoids To test the solenoids press START to energ
42. aler area or not 1425 513500 0 380 513300 0 Template 7 2 22 Offset Feeder 1 01425 513500 5 01380 513300 5 7 2 23 OMR Offset Feeder 2 01425 513500 115 Swiss Offset 165 01380 513300 115 Swiss Offset 165 7 4 5013333 DI380 DI425 SI3300 S13500 Service Manual 7 Service Menu amp Troubleshooting 7 2 24 Clear Deck Delay The Clear Deck function is inhibited until the Inserting Machine has been stopped for a period of time to ensure that the Mailing Machine has processed all mail and stopped before clear deck is carried out This avoids the operator transferring material from the Inserting Machine through the Mailing Machine and applying a frank to this material The time is adjusted in the Inserting Machine and Mailing Machine so the Mailing Machine deck rollers and sensors stop being active before the Clear Deck function is carried out in the Inserting Machine The time is adjustable on the Inserting Machine through a new service parameter The perameter range is O to 101 seconds with a default value of 20 seconds The time is set on the Mailing Machine through the operations screen and timeouts menu It is advised that the timeout for the Mailing Machine is less than the Inserting Machine DI425 S13500 20 1380 513300 0 7 2 25 MMI Stack Limit This is the number of envelopes that can be stacked on the deck of the Mailing base This should only be adjusted depen
43. ame time the envelope motor M9 is energized An envelope is fed through the separator pad and roller The transported envelope will stop in the insertion area at a predetermined time according to the size of envelope programmed within the job setup The insertion solenoid L1 energizes followed by the hold down solenoid L2 and finally by the shoe horn solenoid L3 When the shoe horn solenoid is energized the software sends a signal to operate the insert collation motor M4 This will trigger the next insert to be fed into the collation insert area When the insert enters onto the pivot plate this moves the flag out of sensor OP5 When the insert is fully inserted the pivot plate moves backwards returning the flag to its home position This operation triggers the software to energize the finger solenoid L4 lifting the fingers and lifting the brush of the sealer by energizing solenoid L5 It will then de energize the hold down solenoid L2 insertion solenoid L1 and the shoe horn solenoid L3 The envelope will then be driven from the insertion area into the sealer area The next envelope will be fed when the lead edge of the envelope pushes the moistener sensor S3 forward the software will increment by a count of 1 for the EIU The envelope will then enter the inverter area and then exit into the stacker The exit sensor S4 will increment the mechanical counter located behind the manual advance knob door by 1
44. and the start button is pressed the sheet feeder motor M1 is switched on This feeds a sheet over the Double Document Detector DD1 sensor and stops it after a counted delay in the collation nip This results in the sheet being slightly over driven At the same time the envelope motor M9 is switched on and an envelope is fed through the separator pad and roller When the lead edge of the envelope moves forward to the envelope sensor S1 the software sends the signal to turn on the collation motor M5 The transported envelope stops in the insertion area at a predetermined time according to the size of envelope programmed within the job setup The insertion solenoid L1 energizes followed by the hold down solenoid L2 and finally by the shoe horn solenoid L3 Depending on fold type the sheet will be fed through the fold rollers and fold plates The folded sheet enters onto the pivot plate this moves the flag out of sensor OP5 When the folded sheet is fully inserted the pivot plate moves backwards returning the flag to its home position this de energizes the hold down solenoid L2 and the shoe horn solenoid L3 L3 energizes again placing the shoe horn back into the envelope lifting the previous folded documents up The software sends the signal to turn on the collation motor M5 sending the next sheet down through the fold rollers and fold plates onto the pivot plate This happens until the predetermined sheets are inser
45. andle get smaller board in the machine is better protected than one which is not plugged in a chip on a board is better protected than one in your hand e Stay away from metal conductors The plastic and resin that chips and boards are made of are much better insulators than metal It s most important to keep your hands away from any metal which contacts the data In particular this means the long connector along the bottom of each board and the pins coming out of the chips These signal and data lines are directly connected to the fragile inner circuits of the chips When handling a board try not to touch the connector when handling a chip try not to touch the pins SDT3233A DI380 DI425 SI3300 S13500 Service Manual 2 1 2 Specifications MATERIAL SPECIFICATIONS Sheet Feeders Minimum sheet size 127mm Width 127mm Length Maximum sheet size 229mm Width 406mm Length Paper weights 60g m Minimum non OMR 70g m Minimum 120g m Maximum Fold configurations Material length limits before folding Single fold 127mm 315mm Letter fold 150mm 356mm Z Accordion fold 201mm 356mm Double fold 305mm 406mm Double Document Detector Material range 60g n 16 Ib Min 1209 32 Ib Feed tray capacity 01380 513300 Up to a maximum of 325 sheets 80g m 01425 513500 Up to a maximum of 325 sheets of 80g m Manual Feed Mode Stapled sets up to 5 sheets of 80g m to a maximum total weigh
46. any loose or detached parts Remove Feeder Trays Fold Plates and Insert Feeder assembly Remove all covers front and rear Check the condition of all belts Insert Feeder Replace Cleaning Pad Assembly Replace Separator Roller Check clean Carriage Rollers upper and lower Clean out of and carriage complete sensors Replace Pre Feed Rollers Lightly lubricate shaft cam with grease Fold Rollers Clean all Fold Rollers you must remove carriage complete assembly side brackets first for easier access Clean fold plate sensors Sheet Feeders Replace Separator Roller Replace Separator Pad Check clean Lower Collation Rollers Clean all out of paper and interlock sensors Sealer Replace Sealer Felt Check clean Transport Rollers Check clean Sealer Brush Inverter Exit Check clean Sealer Rollers driven and idler Check clean Exit Rollers driven and idler Envelope feed Replace Separator Pad Replace Pre Feed Rollers Clean all sensors with a damp cloth or use a brush air duster to remove any surface dust Lightly lubricate the following with grease Handcrank gear spindles Cam on Insert Envelope Drive Clean bobbins and rollers with Isopropyl Alcohol or equivalent cleaning agent Reassemble machine and test SDT333A DI380 DI425 SI3300 S13500 Service Manual 9 Installation 9 1 1 2 Unpack and check machine for damage Locate the machine o
47. ard to the envelope sensor S1 the software sends the signal to turn on the collation motor M5 The transported envelope will stop in the insertion area at a predetermined time according to the size of envelope programmed within the job setup The insertion solenoid L1 energizes followed by the hold down solenoid L2 and finally by the shoe horn solenoid L3 The next sheet fed from the sheet feeder 1 is triggered by the previous sheet fed entering the fold plate 2 sensor OP14 When the folded sheet enters onto the pivot plate this moves the flag out of sensor OP5 When the folded sheet is fully inserted the pivot plate moves backwards returning the flag to its home position This operation triggers the software to energize the finger solenoid L4 lifting the fingers and lifting the brush of the sealer by energizing solenoid L5 It will then de energize the hold down solenoid L2 insertion solenoid L1 and the shoe horn solenoid L3 The envelope is then driven from the insertion area into the sealer area The next envelope is fed when the lead edge of the envelope pushes the moistener sensor 53 forward the software will increment by a count of 1 for the EIU The envelope then enters the inverter area and finally exits into the stacker The exit sensor S4 will increment the mechanical counter located behind the manual advance knob door by 1 This sequence is shown in flow chart form on the following page 5017333
48. at least 50 SDT333A DI380 DI425 SI3300 S13500 Service Manual 9 7 Service Menu amp Troubleshooting FAULT FINDING CHARTS Error Codes Operator Check List Service Diagnostic Connector Replacement and fault Logic Test Parts 201 Fold Plate 1 not set 202 Fold Plate 2 not set E03 Exit ramp not set 204 Feeder 1 empty 205 Feeder 2 empty E06 Feeder Insert empty 07 Envelope Feeder empty E08 Feeder 1 DDD blocked prior to start of a cycle 09 Feeder 2 DDD blocked prior to start of a cycle E10 Insert DDD blocked prior to start of a cycle 10 Remove fold Plate and check for jammed material Check for any binds Check Clean fold plate sensor Remove fold Plate and check for jammed material Check for any binds Check Clean fold plate sensor Open inverter door and check for any material Check material is loaded in feeder 1 Check material is loaded in feeder 2 Check material is loaded in feeder 3 Check material is loaded in envelope feeder Open top cover and check jam access plate for any material Close jam access plate Remove feeder 2 and check for any material Remove the insert feeder open the carriage complete assembly and check for any material Test end stops position Test fold plate sensor OP13 Test motor count and stop for fold plate 1 M6 Test end stops position Test fold plate sensor OP14 Test motor count and stop for fold plat
49. c board Drain the water from the sealer unit Undo the screws holding the AC motor cover Undo the wiring holding the on off switch and AC input filter noting the orientation of the wiring Loosen the AC belt tension and remove the drive belt When reassembling take note of the Caution below Undo the bracket holding the AC encoder sensor this also holds the AC motor Undo the rest of the screws retaining the AC motor Tilt the machine back and undo the 4 feet holding the base plate and remove the plate Disconnect connectors P35D sensor 4 power supply unit and all other wiring into the power supply unit motor start capacitor and AC inputs Undo the 4 screws holding the Power supply unit and remove the unit Unclip the motor start capacitor from the holder as this is wired to the AC motor and remove both the AC motor and motor start capacitor Reassemble in reverse order CAUTION When reassembling the AC motor drive belt adjust the tensioner to take up the belt slack DO NOT OVERTENSION Overtensioning of the belt will induce premature failure Note for countries using 60Hz AC The motor uses a smaller diameter drive pulley This will affect the drive belt tension and the tensioner will be lower to take up more tension 5013333 DI380 DI425 SI3300 S13500 Service Manual 4 17 4 Removal amp Replacement 4 18 5013333 DI380 DI425 SI3300 S13500 Service Manual 5 Adjustments 5 1 ENVELOPE FEED TRAY G
50. cates Count 0 Press the Change button until the count reads 350350 This is the code that enables Enhanced OMR Press the Start button The display shows Enhanced OMR Mode Is ON 6 Exit Set Parameters per your usual procedures 6 16 3 Switching Off OMR To switch off enhanced OMR 1 Open the hinged cover to the right of the OMR display 2 Press the Change button to enter Access Code 17 Press the Next lt button until the option Set Parameters appears then press the Start button 4 Press the Next lt button until the option Set Basic Mode appears then press the Start button 5 he display shows Basic Mode Is OFF Press the Change button until the display shows OMR Basic Mode is ON Press the Stop button This enables Basic OMR 6 Exit Set Parameters per your usual procedures 7 Both Basic and Enhanced OMR will now be switched Off SDT3233A DI380 DI425 SI3300 S13500 Service Manual 6 17 SCANNING TEMPLATE A combined Scanning Template and OMR Sensor Set Up document is available from IDC stock un der form number SDT316 For your information a reduced size reproduction is shown below I Vertically Centre Group within i a Clear zone 20mm x 115mm min Y Location of bottom tray sensor test area on reverse FEED DIRECTION FOR BOTTOM SCANNING OMR Scanning Template MARK SPECIFICATIONS The Scan Dash Mark should be a minimum
51. cord should be updated when any setting s are changed 7 2 1 Final Assembly Number This is to set the machine s configuration F3E1 01380 EAME 1 station F3E2 DI380 EAME 2 station 01380 EAME 3 station 4 01380 1 station OMR 5 01380 EAME 2 station OMR F3E6 01380 3 station OMR F3F1 01425 EAME 1 station F3F2 01425 EAME 2 station F3F3 01425 EAME 3 station F3F4 01425 EAME 1 station OMR F3F5 01425 EAME 2 station OMR F3F6 01425 EAME 3 station OMR Note If the configuration is changed via the Final Assembly Number all jobs previously stored will be deleted 5013333 DI380 DI425 SI3300 S13500 Service Manual 1 7 Service Menu amp Troubleshooting 7 2 2 Set Default Job This sets the Default Job 0 Zero 7 2 3 Set 50 60Hz To set the frequency of the Mains supply Factory set 7 2 4 Serial Interface Meter Interface used for online solutions Event Logging Used by Engineering to monitor and Software processing Data Logging Used by Engineering to monitor and Software processing 7 2 5 View Error codes This allows you to view the last 10 Error Codes E01 E126 7 2 6 Set DDD This sets the position of the reference point of the DDD Sheet feeders 1 and 2 Leading Edge Sample At Middle e Trail edge Insert feeder e Leading Edge 7 2 7 Set Service Counter This sets the software counter For EIU use o
52. crews on both sides Remove springs E clips and bearings from upper and lower sealer roller shafts Loosen the water tank on rear side Remove sealer exit drive belt by removing E clip gear pin bearing and wavy washer and withdraw roller from the base Reassemble in reverse order 5013333 DI380 DI425 SI3300 S13500 Service Manual 4 13 4 Removal amp Replacement 4 17 REMOVAL THE INVERTER MOTOR ASSEMBLY 1 2 Disconnect power Remove the 8 screws from the inverter ramp 4 long and 4 short Note Access is now gained to the motor and encoder board If the plastic bearings removed via the motor and encoder make sure the bearings are correctly located on reassembly Reassemble in reverse order 4 18 REMOVAL OF THE CONVEYOR TRANSPORT BELTS AND ROLLERS 1 4 14 Using the job setup program set the envelope depth to 162mm before switching off This will give greater access to the rollers Follow instruction for cover and PCB removal in section 4 1 Follow instruction for top assembly removal in section 4 9 Disconnect connector on the rotary solenoid in the Q station Unclip the Q station from its location Remove both springs and unclip sealer brush assembly Remove sealer shield that is held in place by 2 screws on the front and rear sides CAUTION Take care not to damage the switch Remove the upper conveyor idler roller by removing 2 springs E clips and bearings from both the front and rea
53. d a typical configuration For a formal Declaration of Conformity please contact Compliance Engineering on 44 0 1279 426731 ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTIFICATION AND ARE SUBJECT TO TEST 5013333 DI380 DI425 SI3300 S13500 Service Manual 3 1 3 Theory of Operation Note Before any job commences it is assumed that all the appropriate trays are filled to complete the sequences described below Please refer to relevant diagrams in Section 10 Diagrams INTRODUCTION TO SYSTEM THEORY 01380 513300 and 01425 513500 are low volume easy to use Folding Inserting machines each available in 3 variants 1 2 and 3 station machines The sheet feeder s have self centring guides and automatic separation based on photo copier technology Therefore the documents do not require shingling before the they are presented to the separator roller and pad The sheet feeders have a sprung lift plate that lifts the weight of the documents up to the separator roller to ensure only a single document is fed The insert feeder has a more traditional type of separation by means of a manual height adjustment and a stone shield setting that is operator settable This is to enable diverse material to be processed through the insert feeder The envelope feeder will automatically separate a stack of envelopes to ensure only a single envelope is fed The separator height is set by the engineer When the Start button is pres
54. dant on the thickness of the envelopes 1425 513500 4 e 01380 513300 4 SDT333A DI380 DI425 SI3300 S13500 Service Manual 7 5 7 Service Menu amp Troubleshooting 7 3 SERVICE DIAGNOSTICS Diagnostics allows the engineer to test every component by using the control panel Normal state shows the state of the sensors with all feeders and fold plates fitted and with no mate rial loaded in the machine 7 3 1 Test Sensors See section 7 4 2 for instructions on how to test Normal State Test DDD Sensors Sheet Feeder 1 255 Sheet Feeder 2 255 nsert Feeder 255 Test Tray Sensors e Sheet Feeder 1 Clear Sheet Feeder 2 Clear Insert Feeder Clear Envelope Clear Daily Mail Off On Insert Feeder Interlock Blocked Envelope Load Switch Off On DI425 813500 ONLY Test Paper Sensors e Transport Plate Clear Envelope Feed Sensor Clear Envelope Lead Edge Sensor Clear e Moistener Clear Exit Sensor Clear Test Home Positions Fold Plate 1 Clear Fold Plate 2 Clear e Q Station Clear Inverter Clear Half Fold ON Blocked Clear Half Fold OFF Clear Blocked Envelope Platform Up Clear Blocked 01425 513500 ONLYY Envelope Platform Down Blocked Clear 01425 513500 ONLY Test Interlocks Hand Crank Interlock Closed Fold Plate 1 Interlock Closed Fold Plate 2 Interlock Closed Collation Interlock Closed Flapper Cover Interlock Closed Se
55. e a minimum of 12mm overall This measurement should be taken with all Mail Piece contents placed into the envelope The Mail Piece Contents must allow a minimum clearance of 3mm for unfolded inserts and 6mm for folded material below the flap crease after being fully inserted into the envelope Envelope flap and throat requirements Min 25 5mm Max 63mm E ces Min 6mm Max 41mm 19mm Min 1 6mm Max 6mm Mug E Closed flap tip should not come closer than 44mm to bottom of envelope throat depth at 19mm in from edge of envelope ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTIFICATION AND ARE SUBJECT TO TEST 5013333 DI380 DI425 SI3300 S13500 Service Manual 2 3 2 Specifications 2 2 2 4 MACHINE SPECIFICATIONS Physical Dimensions 80 0 Length 773mm 1043mm Depth 568mm 568mm Height 525 525 Weight 55kg 65kg Weight will depend on machine configuration Weights stated do not include material Noise Level Running 73dBA Electrical 230VAC 50Hz 3A 110VAC 60772 Maximum Speed 01380 513300 Up to a maximum of 3 000 cycles per hour DI425 813500 Up to a maximum of 3 500 cycles per hour Depending on model fold type and material quality requirements of the Low Voltage Directive 73 23 EEC and the EMC Compliance It is certified that the Folding Inserting machine complies with the C 6 Directive 89 336 EEC The product was teste
56. e 2 M7 Test end stops position Test sensor OP6 Test motor count and stop for M11 Test out of paper sensor OP9 Test out of paper sensor OP10 Test out of paper sensor OP11 Test out of paper sensor OP12 Test DDD 1 sensor level Check alignment of DDD1 connectors Test DDD 2 sensor level Check alignment of DDD2 connectors Test DDD3 sensor level Check alignment of DDD3 connectors 5013333 DI380 DI425 SI3300 S13500 Service Manual P29 pins 6 7 8 P17 pins 1 2 P17 pins 3 4 5 17 pins 6 7 8 P29 pins 1 2 P29 pins 3 4 5 P36 pins 3 4 5 P36 Pins1 2 P36 pins 3 5 6 P20 pins 19 20 21 P19 pins 12 13 14 P24 pins 4 5 6 P14 pins 20 21 22 50 drop on display screen Check for 5096 drop on display screen Check for 5096 drop on display screen Sensor OP13 Motor M6 Encoder Sensor OP14 Motor M7 Encoder Sensor OP6 PCB Motor M11 Encoder Sensor OP9 Sensor OP10 Sensor 11 Sensor OP12 Replace DDD sensor PCB s Replace DDD sensor PCB s Replace DDD sensor PCB s 7 Service Menu amp Troubleshooting Error Codes Operator Check List Service Diagnostic Connector Replacement and fault Logic Test Parts E11 Envelope Open the flapper cover Test envelope feed sensor P14 pins 18 amp 19 Replace sensor feeder sensor blocked prior to start of a cycle E12 Sheet feeder1 paper too short E13 Sheet feeder 2 paper too short E14
57. e by hand to remove any material Possible motor bind Check and reset Check exit switch S4 and entry sensor on the VPS Check docking switch on VPS Check docking switch on VPS Check internal RS232 cable to PCB Check drive belt gear from inserter to MMI 5013333 DI380 DI425 SI3300 S13500 Service Manual 7 Service Menu amp Troubleshooting Error Codes Operator Check List Service Diagnostic Connector and Replacement and fault Logic Test Parts E126 Processor Power off Power on Reset 5013333 DI380 DI425 SI3300 S13500 Service Manual 7 21 7 Service Menu amp Troubleshooting 22 5013333 DI380 DI425 SI3300 S13500 Service Manual 8 Preventive Maintenance 8 1 GENERAL INFORMATION Servicing has been broken down into service procedures at 100 000 cycle and 200 000 cycle intervals so that the following items are either checked cleaned or replaced Reflective and DDD sensors must be cleaned on every E call Before attempting to service this equipment discuss with the operator any operational problems 8 2 THE 100K SERVICE aee Oe De c 19 16 17 18 Check that all material falls within specification Check operation of equipment Check operation of safety interlocks Listen for any unusual noises Visually check for any loose or detached parts Remove Feeder Trays Fold Plates and Insert Feeder assembly Remove all covers front and rear Check the condi
58. e g 96mm 196mm Fold 2 Fold Panels 2 standard 80g m sheet from either sheet feeder 3 Measure Fold 1 in millimetres e g 98mm 2mm too long 5 Adjustments 4 Take the actual fold dimension and subtract the displayed job setup figure e g 2 5 Enter this difference positive or negative into the Fold 1 Offset setting in the parameters menu then leave diagnostics 6 Run another standard 80g m sheet and check that the Fold 1 length in job setup now matches the actual fold length Step 2 Fold Plate 2 setting DO NOT carry out this adjustment until Step 1 above is successfully completed 1 Make a note of Fold 2 length as displayed in job setup e g 196mm 2 Runa standard 80g m sheet from either sheet feeder 3 Measure Fold 2 in millimetres e g 202mm 6mm too long 4 Take the displayed job setup figure and subtract the actual fold dimension e g 6mm 5 Enter this difference positive or negative into the Fold 2 Offset setting in the parameters menu then leave diagnostics 6 another standard 80 sheet and check that the Fold 2 length in job setup now matches the actual fold length 5013333 DI380 DI425 SI3300 S13500 Service Manual 5 5 Adjustments 5 11 5 12 5 8 NESTING CONSTANT Before proceeding with this adjustment check that the Fold Offset is set correctly as described in section 5 10 The Nesting Constant adjustment sets the timin
59. e rear of the machine and also the earth strap at the front of the machine Release tensioner on Envelope Platform Motor drive belt and remove Remove screws B fixing plastic plate to the main side frames two screws each side Lift envelope feeder and unhook from main machine Reassemble in reverse order Removing the Envelope Feeder will give access to MTR 20 4 13 REMOVING ENVELOPE FEED ROLLERS 8 SEPARATOR PAD 01425 513500 ONLY 1 2 Remove envelope feeder covers Remove Envelope Feed Motor M 9 and mounting bracket from rear of machine Remove envelope feed roller assembly Remove two fixing screws from separator pad assembly and lift out Reassemble in reverse order SDT333A DI380 DI425 SI3300 S13500 Service Manual 4 11 4 Removal amp Replacement 4 14 REMOVAL OF FLAPPER ASSEMBLY AND BLADE Flapper Assembly 1 11 Follow instruction for cover and PCB removal in section 4 1 2 Remove the 2 screws on the hinge on the front and rear sides Take care not to drop the spacers It may be necessary to remove the large E clip white gear and pin 3 Remove the E clip on the rear side Withdraw the shaftthrough the on the same side and separate the assembly from the base Blade 5 Remove 4 screws from the tinted cover 6 Remove the flapper unit springs noting the position of the different colour springs 7 Remove the 2 inner screws on each side of the assembly front and rear o
60. e roller bonded to the shaft Reassemble in reverse order The machine should be in a half fold mode before attempting to remove the fold roller Follow instruction for cover and PCB removal in section 4 1 Release belt tension Remove 2 E clips pins and the white pulleys located next to the insert motor bracket on the front side of the machine Remove 4 fold roller springs on the front and rear side of the machine taking note of the position of the different strength springs Care SDT333A DI380 DI425 SI3300 S13500 Service Manual Clips Pins 8 White Pulleys FOLD ROLLER REMOVAL REPLACEMENT BW 774 A eu Tut 4 a Continued 4 5 4 Removal amp Replacement 5 Remove 4 fold roller springs on the front andrear side of the machine taking note of the position ofthe different strength springs Care should be exercised when removing these springs 6 Remove 4 E clips and bearings from the front side E Clips Roller 7 Remove 4 E clips wavy washers and amp Bearings 4 Springs bearings from the other end of the fold WE rollers on the rear side 5 8 Remove 2 screws that hold the bracket to the half fold deflector Half Fold Deflector Screws 9 Remove 6 screws from the fold roller access j 22 plate the rear side 6 Access Plate gt Screws 10 Remove half fold deflector and roller com
61. e safety awareness The following is a list of general precautions which cannot be over emphasised e HIGH VOLTAGE is present at certain points the equipment INJURY or DEATH could result if you fail to observe safety precautions 6 Know how to turn off power in the work area and how to summon help in case of emergency e Do not work on equipment under power unless absolutely necessary SDT3233A DI380 DI425 SI3300 S13500 Service Manual Introduction 1 e When working on live circuit use extreme caution Don t grasp two sides of a live circuit at the same time e Always use the right tools for the job Treat every circuit like gun which may be loaded may not be live but be sure Check with neon tester a voltmeter or simply unplug the machine e Use one hand when reaching into a circuit By keeping one hand free lethal current is less likely to pass through vital organs Observe this rule when connecting or disconnecting plugs or leads and when making any adjustments on a live circuit Don t underestimate the danger of shock 1mA 1 1000 ampere is uncomfortable 5 mA 1 200 ampere is dangerous the victim may jump back and be injured 12 mA 1 83 ampere causes hand muscles to contract the victim cannot free himself 24 mA 1 40 ampere has proven fatal and 100 mA 1 10 ampere is likely to be fatal e Don t reach into a circuit with metal tools or while wearing rings or watch Even in low voltage c
62. en be able to automatically work out the length of the code BOC NOT AND EOC NOT Two mark positions are allocated to this function one NOT BOO to indicate that a sheet is not the beginning of a set and one NOT EOC to indicate that a sheet is not the end of a set For a single sheet set neither mark is printed for intermediate sheets in a three or more sheet set both marks are printed See Figure Allowable Mark Combinations for Basic OMR Diagram Pg 6 9 For both C double and Z single fold jobs the NOT EOC mark is printed on every page but the first page of each collated set the address bearing page whose address appears through the window of the envelope which will always be the last page fed into the inserter The NOT BOC mark is printed on every page but the first page of each collated set which will always be the first page fed into the inserter PARITY AND OTHER CHECKS The OMR code includes a parity mark and other fixed marks The parity mark is used for error check ing and is printed such that the total number of marks printed including the parity mark benchmark safety mark and retiming mark s is even If an error is detected the machine will stop with an explanatory error message and await manual recovery Most errors will stop before the erroneous sheet has been folded to allow the operator to evaluate the error and where appropriate to place the sheet back in the feeder and in proper order before continui
63. ertion shaft and transport plate centre spring 4 Move the limit plate until it touches the transport plate arm Re tighten screw A This adjustment will achieve a 4 5 gap when the transport plate is in its actuated position STEP 2 1 Re fix the Opto Bracket Setting Gauge but still allow movement of the bracket 2 Adjust the Opto Bracket until the underside of the transport plate arm contacts the leg of the bracket This adjustment will achieve the correct flag position in the sensor when the transport plate is in its resting state Screw A Limit Plate Step 1 contacts Transport Pivot gauge Plate step 2 Insertion Roller 5 Sensor OS ES pivoting 4 5 setting Transport Pivot Plate Setting 5013333 DI380 DI425 SI3300 S13500 Service Manual 5 10 FOLD PLATES 1 AND 2 OFFSET It may be necessary to set an offset value for each Fold Plate in order to make actual fold panel sizes agree with the dimensions indicated on the machine s display in setup For this procedure you will need to refer to the machine s display which will indicate default panel sizes for sheets of 297mm or 279mm in length The illustration is for a 297mm A4 sheet with a standard fold Before carrying out the settings below set the Fold 1 Offset and Fold 2 Offset in Parameters menu to zero Step 1 Fold Plate 1 setting 1 Make a note of Fold 1 length as displayed in job setup
64. ew on the cradle and split the separator housing to remove the separator roller complete with nylon bearings and cradle from the large insert feeder moulding Remove the separator rollers Note direction of drive 5013333 DI380 DI425 SI3300 S13500 Service Manual 4 7 4 Removal amp Replacement 4 9 4 8 DISMANTLING INSERT FEEDER 01425 513500 1 2 10 11 12 13 14 Remove insert feeder Detach wedge from feeder Unscrew the 4 screws holding the top cover from the insert feeder tray and remove top cover Turn the whole unit over onto its back Remove 4 screws from the bottom tray which are holding the side walls to the tray Turn the whole unit back over and remove the 2 screws holding the bracket to the upper pre feed roller Wind the side guides out to maximum Carefully remove the assembly and side frames Disconnect the paper sensor from the hot shoe Remove any restricting cable ties to gain access to the unit Remove the E Clips pins and pre feed rollers from the pre feed shafts Take note that the upper rollers are clutched and the lower pre feed rollers are fixed on the D shaft Remove the screws holding the motor bracket assembly and bearing and then remove the motor bracket assembly and bearing Remove the E Clip gear and pin then remove the 2 screws holding the cleaning pad and loosen the centralising allen screw from the top of the unit Removing the casting screw to enable you to spl
65. f the blade 8 Remove the 2 E clips on the inside of the 2 outer rollers 9 Withdraw one side of the frame 10 Withdraw the rollers and flapper blade o ak 177 Hinge Screw 1 each side Y T SE 9 hs TAMA 5 B Silver Reassemble in reverse order ensuring the flapper blade moves freely 5013333 DI380 DI425 SI3300 S13500 Service Manual 4 4 15 REMOVAL OF THE TRANSPORT PIVOT PLATE 8 INSERTION ROLLER 1 Follow instruction for cover PCB removal in section 4 1 Follow instruction fortop assembly removal Shoe Horn A Shaft Screw in section 4 9 Remove the 2 screws that hold the shoe horn shaft assembly in place and remove shaft from the base Remove all E clips drive gear pin wavy washer and bearing from both the front and rear end of the shaft Remove the shoe horn buffer stop the operator side Press down hold down fingers and remove Transport Pivot Plate roller Allen Screw To remove screw and sensor limit arm Using a 2 5mm allen key undo the Allen screws from both ends of the transport pivot plate then remove the sensor arm attached to the plate Reassemble in reverse order Re align transport pivot plate to rollers ensuring that they do not bind 4 16 REMOVAL OF SEALER ROLLERS 2 Disconnect power Remove the sealer covers only Remove inverter plate held in by 4 s
66. f the sealer by energizing solenoid L5 It will then de energize the hold down solenoid L2 insertion solenoid L1 and the shoe horn solenoid L3 The envelope is then driven from the insertion area into the sealer area The next envelope is fed when the lead edge of the envelope pushes the moistener sensor S3 forward the software will increment by a count of 1 for the EIU The envelope then enters the inverter area and finally exits into the stacker The exit sensor S4 will increment the mechanical counter located behind the manual advance knob door by 1 In normal run mode if no material has been detected at the Double Document Detection sensor the sheet feeder motor M1 will time out after approximately 2 seconds This is to clean the separator roller and pad In daily mail manual feed mode this time is increased to approximately 20 seconds for operator loading The manual feed lever opens the gap between the separator roll and pad In switchable mode the software will activate sheet feeder 2 automatically if the tray empty sensor OP9 detects that no paper is present in sheet feeder 1 when the document has entered fold plate 2 OP14 The software will then switch back to running sheet feeder 1 when the sheet feeder 2 tray empty sensor OP10 detects that no paper is present in sheet feeder 2 when the document has entered fold plate 2 OP14 This sequence is shown in flow chart form on the following page 50173333 D
67. fitting the new pad 6 Reassemble in reverse order 4 2 5013333 DI380 DI425 SI3300 S13500 Service Manual 4 Removal amp Replacement 4 4 REMOVING CARRIAGE ASSEMBLY 1 Follow instruction for cover removal in section 4 1 2 Disconnect connector P23C on rear side 3 Remove the 2 holding plates see illustrations and screws on both the front and rear sides of the machine 4 Remove carriage assemble from the machine 5 Remove 4 self tapping screws from the assembly to expose sensor 6 Reassemble in reverse order E i PP Sh aby i a 5013333 DI380 DI425 SI3300 S13500 Service Manual 4 3 4 Removal amp Replacement 4 5 4 4 REMOVAL OF LOWER COLLATION ROLLER 1 The machine should be in a half fold mode before the lower collation rollers can be removed This allows easier access to the half fold deflector assembly Follow instruction for cover and PCB removal in section 4 1 Follow instruction for removing sheet feeder motor bracket assembly section 4 3 steps 1 3 Disconnect P24B from the Insert collation encoder PCB Remove the insert motor bracket assembly from front side held with 3 screws Unlatch the Jam Access cover On front and rear sides remove sheet feeder 2 tray mounts Disconnect PB16A from hold fold deflector motor and PB16B from half fold encoder PCB Remove 2 screws securing the half fold worm drive to the deflector plate Remove the E clip and gear
68. fold plate indicated and check for any material Check that the paper used matches the paper size programmed in job set up Remove fold plate indicated and check for any material Check that the paper used matches the paper size programmed in job set up Power machine off on if the fault is still present call service Remove and refit the feeder 1 tray Remove and refit the feeder 2 tray 7 Service Menu amp Troubleshooting Error Codes Operator Check List Service Diagnostic Connector and Replacement and fault Logic Test Parts Test out of paper sensor 11 Test the insert feeder motor M3 Test encoder Test the collation motor 4 Test encoder Test lead edge sensor S2 Test envelope sensor S1 Check the main drive belts gear and pins Test fold plate sensors OP13 and OP14 Test collation motor M5 Test encoder Test main fold roller drive Test fold plate sensors OP13 and OP14 Test collation motor M5 Test encoder Test main fold roller drive Check main and motor software proms on the main PCB Test sheet feeder sensor OP1 Test sheet feeder sensor OP2 5013333 DI380 DI425 SI3300 S13500 Service Manual P24 pins 4 5 6 Sensor OP11 Motor M3 Encoder 27 pins 1 2 P27 pins 1 2 3 P25 pins 1 2 and Motor 4 26 pins 1 2 P24 pins 10 11 12 Encoder Sensor S2 Sensor S1 P35 pins 11 12 P14 pins 18 19 Sensor OP13 OP14 OP13 P29 pins 6 7 8 OP14 P17 pins 6 7 8 P
69. g Guide German Hefter Branded SDT334 DI380 DI425 813300 813500 Parts List CONTENTS This manual is organised as follows e Section 1 Introduces the manual 6 Section 2 Lists material and equipment specifications e Section 3 Briefly presents the theory of operation 6 Section 4 Presents removal and replacement procedures 6 Section 5 Gives adjustment procedures e Section 6 Offers information on the OMR system e Section 7 Lists troubleshooting procedures e Section 7 Covers preventive maintenance e Section 8 Provides installation setup and check out instructions e Section 9 Contains schematics and other diagrams SAFETY SUMMARY Warning messages are used throughout this manual to alert you to potentially hazardous conditions These warnings are explained below e WARNING calls attention to improper practices that could cause injury e CAUTION calls attention to improper practices that could damage the equipment or the material being run e IMPORTANT calls attention to practices that could adversely affect equipment operation if instructions are not followed exactly You must familiarise yourself with proper procedures and methods before you install operate or service the equipment to avoid personal injury or damage to the equipment If you are responsible for training service personnel or equipment operators it is incumbent on you to explain safety precautions to your students and encourag
70. g of the insert firing into a folded sheet 1 Enter the Parameters menu and set the Nesting Constant to 12 Mis nested distance 2 Run a cycle and open an interlock Within 5mm is acceptable on the machine to stop the folded sheet on the Transport Plate prior Insert Nesting Adjustment to the insertion area 3 Remove the sheet from the machine taking care to allow the insert to move in relation to the folded sheet 4 The amount of mis nesting can be checked by measuring the amount that the insert is stopping behind the lead edge of the folded sheet 5 To correct unacceptable mis nesting adjust the Nesting Constant in the parameters menu 1 count approximately 0 5mm 6 Run another cycle and interrupt the machine with the sheets on the Transport Plate Re check the insert position and adjust again if necessary Q STATION ADJUSTMENTS 5 12 1 Alignment This adjustment MUST be carried out BEFORE Q Station Calibration Refer to the illustration on the following page 1 2 Enter the Set Parameters menu on the display Choose Q Station Calibration Finger Stop and ensure the value is set to 130mm Place an envelope into the Q Station ensuring that the lead edge of the envelope is touching the Finger Stops Using a ruler measure accurately the distance from the envelope lead edge to the insertion shaft on either side of the Finger Stops marked A and B in the illustration and record the measurements
71. h the machine on Explain the functions of the Display Panel its symbols and buttons Show how to select a pre programmed job Explain that the machine will always request a trial piece when first selecting a job and that the trial piece calibrates the Double Document Detect Sensors Explain how to load material into all feeders Show paper orientation symbols for loading material Explain the 1 4 or 1 2 turn adjustment of side guides to allow clearance Run the job Coverrunning a trial piece checking contents and using batch mode Explain operation of Start Stop Show how to load material while the machine is running Finishing a job Show operator how to check all material has ejected out of machine Material stoppage Explain stoppage location symbols and how to use the Clear Deck button and Manual Advance Knob Show removal of feeder and fold trays to gain access to jam areas Operator Hands Allow the operator to select a new job and adjust all feeders Call avoidance Explain use of the trouble shooting and operating guide Operator maintenance Show how to fill Water Bottle SUPERVISOR TRAINING Carry out the entire Operator Training plus 1 Explain programming of jobs Make sure you explain entering deleting modifying jobs and fine tuning of fold panels Explain the Default Job and if necessary set it to the customer s preferred application Supervisor Hands Get the supervisor to program a job and ru
72. herwise you could damage the equipment SDT3233A 1380 01425 513300 513500 Service Manual 1 3 1 Introduction 1 6 1 4 EQUIPMENT SAFETY Just by walking around you yourself may carry a threat to the equipment in the form of a high voltage electrostatic charge Your body acts as a giant capacitor which can store large amounts of electricity Walking across a rug can charge you with several thousand volts which can discharge in a spark up to an inch long Digital equipment can be easily damaged or destroyed by static charges Microprocessors and other ICs contain tiny transistors not much more than a millionth of an inch across which operate at 5 to 12 volts You don t have to see a spark to ruin an IC 50 volts is enough Follow these guidelines to protect sensitive equipment from static damage e Ground yourself before reaching into the equipment or touching any circuit board or other electrical component Just touching a doorknob or metal workbench may be enough but the best guarantee is to turn the machine off but leave it plugged in and ground yourself on the chassis which is grounded through the three wire power cord If you have access to one bring a grounding strap and use it e Be careful of rugs even a few steps can recharge you Re ground yourself whenever you ve walked away and returned to the machine Rugs are a major source of static buildup in the e Take greater precautions as the objects you h
73. ification 2 1 2 3 2 2 Machine 522222 5 2 4 3 Theory of Operation 3 1 Introduction To System Theory 3 1 3 2 Single Sheet Feeder Mode amp Linked Feeder 3 2 Flow Diagram Single Sheet Feeder Mode 3 3 3 3 0 3 4 Flow Diagram Insert Feeder Mode 3 5 3 4 Two Sheet Feeder 3 6 Flow Diagram Two Sheet Feeder Mode 3 7 3 5 Single Sheet Feeder Plus an Insert Mode 3 8 Flow Diagram Single Sheet Feeder Plus an Insert Mode 3 9 3 6 Two Sheet Feeders Plus an Insert Mode 3 10 Flow Diagram Two Sheet Feeders Plus an Insert Mode 3 11 3 7 The Fold Only TM 3 12 Flow Diagram The Fold Only Mode 3 13 3 8 Accumulation From Main Sheet Feeder 3 14 Flow Diagram Accumulation for Sheet Feeder 1 Mode 3 15 3 9 Double Detect Sensors 3 16 3 10 3 17 4 4 1 Removing Covers and 4 4 1 4 2 Removal of Jam Access Plate
74. ing a run is correct and checks for sequential marks thereafter Wrap around sequence counts from 0 to 7 then back to 0 again 7 Incrementing in order so every page is accounted for See Table on the next page SDT3233A DI380 DI425 SI3300 S13500 Service Manual 6 15 OMR 6 WRAP AROUND SEQUENCE MARKS Counting Page Number Sequence Example 5 page Document WAST WASZ WAS marks are absent Page 7 0 WAS is always the mark position closest to the final re timing mark The WAS marks count up as you go down the stack therefore they count down as the document page numbers increase because the documents are reverse stacked for C fold and double fold or forward stacked but face down for Z fold and single fold For Wrap Around Sequence use Group 1 and Group 3 marks and optionally Group 2 Group2 Marks are not used with in the code Group 3 marks be moved up next to group 1 marks 6 15 1 Mark Code Interpretation Marks for EOC and BOC are specified in negated form Each OMR code must begin with a bench mark followed by a safety mark and must end with a re timing mark The benchmark and safety mark are used by the software to determine the mark spacing for the rest of the code The re timing marks are used to minimize the chance that a code is misread and also as part of an error correction algo rithm Additional re timing marks separate the data marks into th
75. ion Motor 10 10 10 8 Schematic Fold Plates Half 10 11 10 9 Schematic Envelope Feeder AC Hand Crank Manual Advance 10 12 10 10 Schematic P40 Envelope Platform Connector 01425 513500 10 13 10 11 5 P41 Envelope Platform Motor Connector 01425 513500 10 13 10 12 Schematic Insert Feeder 10 14 10 13 Schematic Display PSU va Mata bus 10 15 iV SDT335A MMI Service Manual amp Parts List 1 1 5 1 Introduction This document provides the information necessary to support the installation and site repair of the DI380 DI425 813300 813500 Inserter 1 2 EQUIPMENT COVERED This manual applies to the sheet feeder its accessory equipment and the interface kits required for table top system operation 1 3 RELATED PUBLICATIONS SDC639 DI380 Operating Guide SDC640 DI380 Operating Guide SDC641 DI380 Operating Guide SDC642 DI380 Operating Guide SDC643 DI380 Operating Guide SDC644 DI380 Operating Guide SDC645 DI380 Operating Guide SDC646 DI380 Operating Guide SDC647 DI380 Operating Guide SDC648 DI380 Operating Guide SDC649 DI380 Operating Guide SDC650 DI380 Operating Guide SDC1069 DI380 Operating Guide SDC651 DI380 Operating Guide SDC730 DI380 Operating Guide SDC652 DI425 Operating Guide SDC653 DI425 Operating Guide SDC654 DI425 Operating Guide SDC655 DI4
76. ircuits a metal object can short circuit two terminals e Don t bypass safety devices Three wire outlets 220 240 are designed to ground equipment to make it safe If a live wire shorts to a grounded frame the only result is an open fuse If a live wire shorts to an ungrounded frame the frame itself becomes hot and potentially dangerous A fuse is a weak link in a circuit designed to break down before anything else does The maximum safe current in a circuit is determined by the designers Too large a fuse can pass excessive current damaging expensive equipment Interlock switches are designed to remove power from a circuit when an access door cover or panel is opened When such a switch is cheated or otherwise disabled a safety device has been bypassed If you bypass an interlock for service or diagnostic purposes use extreme caution e Ifyou use air pressure to clean a machine use low pressure 30 psi or less and use eye protection goggles or face masks e When using solvents or cleaning fluids make sure ventilation is adequate WARNING Always be sure the equipment is unplugged before you make any attempt to perform the maintenance outlined in this manual If you must work on a live machine note that line potential is present at the power panel and the motherboard CAUTION DO NOT attempt to adjust key timing parameters in the service menu unless you have been trained and thoroughly understand what you re doing Ot
77. ise and START to de energise To prevent damage the solenoid will energise only for a short time e Finger Solenoid Insert Solenoid e Shoehorn Solenoid e Moistener Solenoid Hold down Solenoid 7 3 5 Test A C Motor This will run the A C motor To run this test all interlocks must be closed 7 3 6 Test Cycle This will run the machine with all components being tested Note Make sure that there is no paper loaded To finish test press stop 7 3 7 Test Display All icons will be displayed 7 3 8 Test Clutch and A C Motor Press START to make the A C Motor run Toggle the START button to set the clutch on and off within this test 7 3 9 Test OMR Sensors e Tray 1 Sensor Clear Blocked Tray 2 Sensor Blocked Clear 7 3 10 Test Service Counter When this is pressed the machine counter increments by 1 7 3 11 Test Interlock Relay When START is pressed the relay energizes on then off 7 3 12 Test Calibration Manufacturing use only e DDD 1 e 0002 e 3 5013333 DI380 DI425 SI3300 S13500 Service Manual 7 4 7 Service Menu amp Troubleshooting 7 3 13 Select Board Manufacturing use only 7 3 14 Test Memory Manufacturing use only Test RAM Test NVM Test ROM TROUBLESHOOTING CHARTS 7 4 1 General Information the customer contacts the service department with an error code the technician should give informati
78. it the casting into 2 pieces to remove the shaft and feed rollers Re assemble in reverse order making sure that the seperation is set correctly Refer to seperator roller height section 5 13 2 5013333 DI380 DI425 SI3300 S13500 Service Manual 4 Removal amp Replacement 4 10 REMOVAL TOP ASSEMBLY 1 2 10 Follow instruction for cover PCB removal in section 4 1 Disconnect counter connector P28K at the AC hand crank Undo the belt tension next to the hand crank gearing and remove the drive belt Remove fold plate 1 motor held by 3 screws and an E clip and washer on the drive pulley shaft Disconnect motor and encoder sensor Disconnect the cables to the hold down solenoid L2 Disconnect the cables for the motor encoder P29B and the motor 29 Remove fold plate 2 motor M7 held by 3 screws an E clip and washer on the drive pulley shaft Remove the belt and drive pulley from the shaft to gain access to the top assembly locating screw Remove the 4 screws that hold the top assembly to the base unit from both the front and rear sides Remove the top assembly from the base unit by the support bar at the top of the assembly Note When refitting ensure the top assembly screw holes are the outside of the base unit side frames SDT333A DI380 DI425 SI3300 S13500 Service Manual 4 9 4 amp Replacement 4 11 4 10 REMOVAL OF ENVELOPE FEED ROLLERS AND SEPARATOR PAD
79. ite background expect to see a Blue light 13 Ifthe sensor light output flashes rapidly set up has failed and it will be necessary to re adjust from the beginning of the procedure 14 The procedure for Sheet Feeder 2 is the same as for Sheet Feeder 1 However as the Scanning sensor is mounted below the paper path it is recommended that you remove Sheet Feeder Tray 1 for easier access The front of the Set Up Sheet SDT316 shows the outline of the Blank and Grey boxes on the rear of the sheet so that you can easily set its position above the scanning sensor EP Du epu IS SDT3233A DI380 DI425 SI3300 S13500 Service Manual 7 Service Menu amp Troubleshooting Prior to any fault finding actions the technician should where possible check the job settings and materials that are being used with the operator 7 1 ENTERING THE SERVICE MENU 1 Press the Setup key under the right control panel cover 2 Enter 17 and press the Next key enter a test press START To exit the test press STOP e scroll through the tests use the Prev and Next Keys change any settings use the Change Keys o save any setting press START 7 2 PARAMETERS MENU The parameters menu allows the engineer to change the NVM settings that are set as defaults by the factory Note settings are unique to every machine They are recorded on the inside of the Collation Top Cover This re
80. ixing A Stop Bracket Actuated Position Hold Down Solenoid Assemblies 5 4 5013333 DI380 DI425 SI3300 S13500 Service Manual 5 Adjustments 5 7 INSERTION HOLD DOWN FINGER REST POSITION 1 Adjust the Limit Stop Screw A so that a gap of 1mm is achieved between the Limit Stop Screw A Insertion Shaft and the top side of the Hold Down Fingers Insertion Shaft Hold Down Fingers Hold Down Finger Rest Position 5 8 TRANSPORT PIVOT PLATE END FLOAT 1 Adjust the Transport Plate end float with the pivot set screws located in both side frames Ensure that the plate has minimal end float but is free to pivot Also ensure that the Insertion Springs are set centrally between the Insertion Shaft Rollers by adjusting the setscrews equally on both sides Once set lock the setscrews with locktite or equivalent This adjustment will allow free movement of the Transport Plate Flag Minimal End Play Insertion Springs Insertion Shaft pud Rollers centralise springs between rollers Transport Plate End Float 5013333 DI380 DI425 SI3300 S13500 Service Manual 5 5 5 Adjustments 5 9 5 6 TRANSPORT PIVOT PLATE SETTING Before performing this adjustment the transport plate must be central and free moving as described in section 5 8 above STEP 1 1 Remove Opto Bracket Setting Gauge from front frame 2 Release screw and move limit plate fully up 3 Position the gauge in between the ins
81. lation Insert Pre Feed Envelope Feed Fold Plate 1 Fold Plate 2 Half Fold Q Station Inverter 727 Grey 10V low V nich 12 ms p 12 _ NEN Orange 10V low 24 high Grey 24V high 24V high Orange Pin 1 and 2 values change to 10V Grey depending on direction of drive 96 _ 5013333 DI380 DI425 SI3300 S13500 Service Manual 10 Diagrams Through Beam Sensor PIN Location Wires Blocked Unblocked Location CB Envelope Present Sensor 911 Yellow 5V high 5 high Envelope Platform Upper Limit IL13 8 10 12 White OV low 5 high Envelope Platform Lower Limit 4 Black OV low low Safe seal clutch PUB PIN Location Location Orange 24V Sealer clutch CL1 P39 1 2 Brown OV Momentary Switch Location Location Black 24V Envelope Platform Up Down IL16 40 7 9 OV PCB Motor Stepper PIN Location Envelope Platform 1 2 3 4 Power Supply Unit PIN Location NNNM 5013333 01380 01425 513300 513500 Service Manual 10 5 10 10 6 Diagrams Test Points Te 11 iav 78 5 Volts Indicator mE 24 Volts Indicator 083 3 9 Volts Indicator 57 Micro Diagnostics Factory Use Only CR58 FPGA Indicator Flashes if OK CR61 OMR Sensors mE Not Used Software Diagnostics PA Not Used Software Diagnostics
82. lored contents the last sheet in the envelope will include address information for use with windowed envelopes to ensure that each set of sheets is addressed to the correct recipient OMR uses extensive error checking to provide an extremely low possibility of the wrong set of sheets being inserted into an envelope The maximum overcount figure is NOT configurable It is set in the software for a maximum of five sheets for C Double and Z folds and 10 for Single fold 50132333 1380 01425 513300 513500 Service Manual 6 1 6 6 2 SPECIFICATIONS The mark must be a solid black line between 1pt 2pts thick 0 35mm to 0 7mm and least 10mm wide The marks should be printed on white paper The paper weight should be between 70 9095 The maximum total compressed thickness of the outer envelope should not exceed 2mmm The paper width should be 203mm to 215mm 8 to 81 2 in This includes A4 and American Letter sizes Each mark position must be evenly spaced and at least 3mm apart An area around the marks should be kept clear from print etc that may be read by the scanner in error this area is called the Clear Zone There should be no print on the opposing face of the sheet immediately behind the Clear Zone Clear Zone 1pt to 2pt 0 35 0 7mm thick 2mm min 2 10 Diagram NOT to scale 6 2 SDT3233A DI380 DI425 SI3300 S13500 Service Manu
83. n 1 Open the hinged cover to the right of the OMR display 2 Press the Change button to enter Access Code 17 3 Press the Next lt button until the option Set Parameters appears then press the Start button 4 Press the Next lt button until the option Select Basic Mode appears then press the Start button 5 The display shows OMR Basic Mode Is OFF Press the Change button until the display shows OMR Basic Mode is ON Press the Stop button This enables Basic OMR 6 Exit Set Parameters per your usual procedures 6 16 2 Enhanced OMR Enhanced OMR includes the Basic OMR features plus selective feed auto batch and wrap around sequencing WAS These Enhanced features are not accessible and are not displayed in menus for OMR machines configured for Basic OMR the customer has purchased the Enhanced option the Pitney Bowes Service Representa tive enables the full set of OMR features through the Service Setup menu by entering the passcode when prompted 350350 Do NOT give this passcode to the customer To enable the Enhanced OMR option 1 Open the hinged cover to the right of the OMR display 2 Press the Change button to enter Access Code 17 Press the Next button until the option Set Parameters appears then press the Start button 4 Press the Next gt button until the option Set Enhanced Mode appears then press the Start button 5 he display indi
84. n a strong level table adjacent to a power socket Allow clearance for the stacker to locate over the right hand edge of the table Remove the tywrap from the Q Station Level Machine by using the adjustable feet and then retighten lock nuts Note Take into account the thickness of the stacker Fit the stacker under the right hand end of machine Fit all feeder trays and fold plates Ensure the wedges are fitted to the correct trays Fix Overlays and Badges supplied for machine Fill the sealer Water Bottle Connect the power lead and turn power ON Check all functions of the machine Make sure Envelope offset and Flapper Blade are set correctly Note Envelopes to feed through the machine centrally adjust if necessary Reference adjustment 5 15 in this manual For OMR machines use the OMR Scanning Template and Sensitivity Setup Sheet SDT316 to calibrate machine OMR Machines will possibly need T1 Clutch Release time to be adjusted depending on the type of envelope flap used to seal correctly When you are satisfied that the machine is working properly carry out the Operator Supervisor training on the following page 5013333 DI380 DI425 SI3300 S13500 Service Manual 9 1 9 Installation 9 2 9 3 9 2 OPERATOR TRAINING 1 10 Show and explain the machine layout and the functions of all the blue knobs including Daily Mail Manual Feed Lever Feeder Trays Fold plates Stacker Switc
85. n rotate the flapper blade until ittouches the spacers and resistance is felt 5 Tighten the adjustment plate screws both sides Paper strips 6 Remove spacers and replace v Adjust Flapper 5013333 DI380 DI425 SI3300 S13500 Service Manual 5 15 5 Adjustments 5013333 DI380 DI425 SI3300 S13500 Service Manual 6 1 6 A BRIEF OVERVIEW ON THIS SYSTEM OMR sensors are fitted to the sheet feeders and are mounted within the machine case They are easily adjustable for the following paper sizes e 8inch wide e A4 e American Letter 8 1 2 inch wide e Intermediate sizes between 203mm to 215mm wide One sheet feeder holds sheets with OMR marks e Sheet Feeder 1 Top or only Sheet Feeder for C fold and double fold e Sheet Feeder 2 Bottom Sheet feeder for Z fold Single fold sheet feeder holding the sheets with OMR marks can feed multiple sheets per envelope The sheet feeder not holding OMR sheets can hold supplementary sheets that you can place under the selective control of the OMR sheets You can also set up the insert feeder to be under the se lective control of the OMR sheets As a result OMR can be used to fill an envelope with a variable number of sheets from one feeder with or without a supplementary sheet and an insert A supplementary sheet and folded insert will be nested with the first sheet in the envelope As OMR allows each envelope to contain tai
86. n the machine 5013333 DI380 DI425 SI3300 S13500 Service Manual 10 Diagrams 10 1 FLOW DIAGRAMS INSERT FEEDER SHEET FEEDER 1 SHEET FEEDER 2 FOLD PLATE 1 CARRIAGE ASSEMBLY FOLD PLATE 2 Flow Diagram 0 INSERT FEEDER SHEET FEEDER 1 SHEET FEEDER 2 FOLD PLATE 1 CARRIAGE ASSEMBLY FOLD PLATE 2 Flow Diagram 0 SDT333A DI380 DI425 SI3300 S13500 Service Manual 10 1 10 Diagrams 10 2 COMPONENT LOCATIONS Not present on system but included for backwards compatibility Not present on system but OP2 included for backwards compatibility 55 Not present on system but included for backwards compatibility DI380 S13300 Not present on system but included for backwards compatibility Not present on system but OP2 included for backwards compatibility al Envelope Platform Up Down Switch 01425 513500 10 2 5013333 DI380 DI425 SI3300 S13500 Service Manual 10 Diagrams 10 3 SWITCHES SENSORS MOTORS SOLENOIDS TEST LEVELS Mechanical Switches Location Wires Open Closed Location Fold Plate 1 Interlock 56 P29 10 11 12 13 Black 24V high 24V high Fold Plate 2 Interlock Yellow OV low 24 high Flapper Interlock P14 Blue OV low 24V high Moistener Cover P36 White OV low low P14 Yellow 5 high White low Insert Feeder Interlock Barrier Switches Location Wires Blocked Unblocked
87. n the plug 7 Service Menu amp Troubleshooting Error Codes Operator Check List Service Diagnostic Connector and Replacement and fault Logic Test Parts Check the material is within spec Check the condition of the separator pad and roller Check the material is within spec Check condition of the pre feed rollers Check separator rollers and stone Test all out of paper sensors Visually check closing of door Check door interlock switch 511 Check logic PCB 5 Development code Check the fuses in the plug and AC inlet socket Check connection on logic PCB Check LED display on logic PCB Check P38 for 0 5 24v Check high low readings on the interlocks relays 5013333 DI380 DI425 SI3300 S13500 Service Manual P14 pins 23 24 25 26 pin 7 5vdc logic pins 1 2 8 24 pins 3 4 9 10 pins 13 14 Separator roller and pad Pre feed rollers Separator rollers and stone Interlock switch 511 Logic Fuses Logic PCB PSU PSU 7 17 7 Service Menu amp Troubleshooting rror Codes Operator Check Lis ervice Diagnostic onnector and Replacemen and fault Logic Test Parts E72 Envelope Feeder Overloaded 01425 513500 E74 System Error Power Down E75 System Error Power Down E81 Bad OMR Marks Spacing E82 No OMR Marks E83 Bad OMR Code Length E84 Bad OMR Code Format E85 Expected First Sheet of Set E86 Not a New En
88. ng the run Where this is not possible the Clear Deck button will eject the unsealed envelope and any sheets in transit The machine will then allow the user the choice of manual review of remaining sheets or automatic folding and ejection of any remaining sheets of the current set SDT3233A DI380 DI425 SI3300 S13500 Service Manual 6 9 6 10 OMR 6 RETIME MARKS Retime Marks are necessary for reliable reading of the code due to the paper speed varying as it feeds With Basic OMR only the first Retiming mark is needed if one or both of the other groups are used the Retime Mark associated with that group s must also be printed Retime Marks must be print on every sheet with in the prime set NOTES The beginning sheet of a set is defined as the first to be picked up and fed This is always the last logical page of a document whether reverse collated in Sheet Feeder 1 or forward collated but face down in Sheet Feeder 2 Similarly the end sheet of a set is defined as the last to be picked up and will always be the address sheet After clearing the deck and before continuing the run the user has only to complete the cur rent set manually and to ensure that the top sheet in the OMR sheet feeder is the last one of the next set to be processed ALLOWABLE MARK COMBINATIONS Collated Set One Page Document Benchmark fixed Safety fixed Page 1 of 1 Not EOC Not BOC Parity Re timing fixed Collated Set M
89. nly 7 2 8 Set Out of Material This setting allows the Out of Paper sensors to be switched on or off for the sheet feeders envelope feeder and the insert feeder 7 2 9 Set Nesting Constant This is the timing of the insert being fed into the second fold panel Initially set by the factory 01425 513500 12 01380 513300 2 5013333 DI380 DI425 SI3300 S13500 Service Manual 7 Service Menu amp Troubleshooting 7 2 10 Calibrate Q Station This is to set the position of the envelope stops Initially set by the factory DI425 813500 0 e DI380 813300 130 7 2 11 Set Fold Plate Offsets This is to offset the fold panel lengths to match the lengths programmed in by the customer Initially set by the factory e Fold Plate 1 e Fold Plate 2 7 2 12 Set Env Stop Count This sets the timing of the inset drive solenoid to energise which determines how hard the envelope drives into the envelope stops Initially set by the factory e DI425 813500 15 e DI380 S13300 15 7 2 13 Set Serial Number This is to set the serial number of the machine EIU Use only 7 2 14 View Software Revision This displays the current level of software 7 2 15 Select OMR Basic Mode When code is entered the following functions will appear e OMR Acc Mode is off e OMR Acc Mode is on e OMR Acc Mode is Acc only 7 2 16 Select OMR Enhanced Enter Code to turn on The Extra Functions will appear in Job set up 71 Enter code 350350 to en
90. nt Detection and feeds the sheet over the Double Document Detector DDD1 sensor and stops after a counted delay in the collation nip This will result in the sheet being slightly over driven At the same time the envelope motor M9 is energized An envelope is fed through the separator pad and roller When the lead edge of the envelope moves forward to the envelope sensor S1 the software sends the signal to energize the collation motor M5 to switch on The transported envelope will stop in the insertion area at a predetermined time according to the size of the envelope programmed within the job setup The insertion solenoid L1 energizes followed by the hold down solenoid L2 and finally by the shoe horn solenoid L3 When the sheet enters fold plate 2 covering sensor OP14 the software switches on the insert motor M4 after a timed delay This delay is the nesting constant set in the parameter screen The next insert is fed after the first insert is nested into the folded sheet When the folded sheet and insert enter onto the pivot plate this moves the flag out of sensor OP5 When the insert is fully inserted the pivot plate moves backwards returning the flag to its home position This operation triggers the software to energize the finger solenoid L4 lifting the fingers and lifting the brush of the sealer by energizing solenoid L5 It will then de energize the hold down solenoid L2 insertion solenoid L1 and the
91. on from the Operator Check List column in the charts only If the fault cannot be rectified then an engineer should attend the call and follow the Operator Check List If this doesn t correct the fault the engineer can probe more in depth using the Service Diagnostic and Connector and Logic Test columns to find a resolution Prior to any fault finding actions the technician should where possible check the job settings and that the materials being used are within specification The charts on the following pages are designed to help diagnose faults quickly and as accurately as possible If you are fault finding using a logic probe connect the red probe clips to P36 5V and the black to pin 5 GND A low signal represents a blocked sensor which is the normal state A high signal represents an unblocked sensor If you are using a multimeter connect the red probe to the required board connector and the black probe to GND chassis The chart below and on the following page gives expected voltages and high or low readings that can be found when testing motors solenoids switches and sensors 7 4 2 Double Detect No readings or signals are given for the Double Document Detect sensors The DDD readings in normal state is 255 To test these sensors place a single sheet between the sensor and make a note of the reading displayed Place two sheets between the DDD sensors this figure should drop by
92. plete through the rearframe Withdraw the other fold rollers from the machine 11 Reassemble in reverse order Note The idler fold rollers have a different length shaft 4 6 5013333 DI380 DI425 SI3300 S13500 Service Manual 4 4 8 DISMANTLING INSERT FEEDER 01380 ONLY 1 2 Remowve insert feeder Detach wedge from feeder Unscrew the 4 screws holding the top cover from the insert feeder tray Remove the four screws holding the side walls to the tray Remove the single screw and washer holding the blue adjustment arm Remove the blue indicator needle and the bridge on the rear side Disconnect the out of paper sensor and remove the side walls Disconnect the insert feeder motor and encoder sensor Remove the e clips pins and pre feed roller from the pre feed Withdraw the shaft but take care to note the orientation of the 1 way clutch Remove the two nylon bearings from the cradle Remove the four screws that secure the motor Two of the screws have 1 long spacers Gently remove the motor from its location Remove the nylon bearing e clips and pin behind the gear nextto the separator rollers To remove the separator rollers from the housing t is necessary to split the insert feeder mouldings Remove the last screw that holds the two halves of the mouldings together then loosen the Allen screw 1 5mm Allen Key that holds the mouldings to the upper shaft Remove the scr
93. quence Marks 6 11 6 12 6 15 1 Mark Code Interpretation 6 11 6 12 6 16 Enabling the Features 4 6 12 6 16 1 Basic OMR 6 12 6 16 2 Enhanced OMR 6 12 6 16 3 Switching Off OMR 6 12 6 17 Scanning Template 6 13 6 18 Procedure for manually setting the sensitivity of the OMR sensors 6 14 SECTION 7 Service Menu amp Troubleshooting 7 1 Entering the Service Menu nens 1 1 7 2 Parameters 7 1 7 5 7 2 1 Final Assembly Number 7 1 7 2 2 Set Default Job 7 2 7 2 3 50 60 2 7 2 7 2 4 Serial Interface 7 2 7 2 5 View Error Codes 7 2 7 2 6 Set DDD 7 2 7 2 7 Set Service Counter 7 2 7 2 8 Set Out of Material 7 2 7 2 9 Set Nesting Constant 7 2 7 2 10 Calibrate Station 7 3 7 2 11 Set Fold Plate Offsets 7 3 7 2 12 Env Stop Count 7 3 7 2 13 Set Serial Number 7 3 7 2 14 View Software Revision 7 3 7 2 15 Select Basic Mode 7 3 7 2 16 Select Enhanced 7 3 7 2 17 Basic Wetter Constant 7 3 7 2 18 Acc Wetter Constant 7 4 7 2 19 T1 Clutch Release Time 7 4 7 2 20 2 7 4 7 2 21 T3 Table Offset 7 4 7 2 22 Offset Feeder 1 7 4 7 2 23 Offset Feeder 2 7 4 7 2 24 Clear Deck Delay 7 5 7 2 25 MMI Stack Limit 7 5 7 3 Service Diagnostics 7 6 7 9 7 3 1 Test Sensors 1 6 7 3 2 Test UART 7 7 7 3 3 Test D C Motors
94. r side and withdraw roller Remove tension from conveyor transport Arching Rollers E belts Par 4 CH Continued 5013333 DI380 DI425 SI3300 S13500 Service Manual 10 11 12 13 14 19 16 17 18 4 On the arching roller push the rearmost bobbin off the pin Remove E clips and bearings from front and rear sides holding the arch roller Withdraw the arching roller from the base by tilting it upwards at the front end Loosen the water tank on non operator side Undo belt tension on sealer exit drive belt Remove the E clip on the operator side holding the transport drive roller Push transport drive roller out of the bearing on the operator side and tilt roller upwards this will allow the removal of the belts The bobbins and pulleys can be removed at this point by removing the 2 inner E clips Reassemble in reverse order Note Water must be drained from the machine before working on any component requiring access from behind the base plate or which requires tipping the machine back onto the supports 4 19 REMOVING LOWER FLAPPER ROLLERS 1 2 10 11 Follow instruction for cover and PCB removal in section 4 1 Follow instruction for top assembly removal in section 4 9 Release belt tension on rear side Remove E clip pulleys pin E clip wavy washer and bearing on rear side Remove E clip and bearing on front side
95. ree groups of three as follows Basic OMR uses only Group 1 Enhanced OMR uses Group 7 plus Group 2 and or Group 3 Benchmark fixed Safety fixed Not EOC this mark should be on all except the last sheet of a collation Not BOC this mark should be on all except the first sheet of a collation Parity set if necessary to give this code EVEN parity Re timing fixed Select Feed 1 on all sheets of a collation that includes a supplementary sheet Select Feed 2 on all sheets of a collation that includes an insert Auto Batch on all sheets of the last collation of a batch Re timing fixed if this group is in use Wrap Around Sequence 3 WAS3 Wrap Around Sequence 2 WAS2 Wrap Around Sequence 1 WAS1 Re timing fixed if this group is in use Group 1 Group 2 Group 3 Identifying the marks for 3 Series 50132333 1380 01425 513300 513500 Service Manual 6 11 6 6 16 6 12 Basic uses only group 1 Enhanced uses group the Group 1 plus Group 2 or Group3 Always include the Group 1 in an OMR code You may include either or both of the second and third groups if these features are needed for a particular job If the Auto Batch function is used the mark must appear on each sheet of the last set of a batch printed in reverse collation and on the first set of a batch printed in forward collation ENABLING THE OMR FEATURES 6 16 1 Basic OMR To enable the Basic OMR optio
96. rs fold plate 2 covering sensor OP14 the software switches on the insert motor M4 after a timed delay This delay is the nesting constant set in the parameter screen The next insert is fed after the first insert is nested into the folded sheets When the folded sheets and insert enter onto the pivot plate this moves the flag out of sensor OP5 When the insert is fully inserted the pivot plate moves backwards returning the flag to its home position This operation triggers the software to energize the finger solenoid L4 lifting the fingers and lifting the brush of the sealer by energizing solenoid L5 It will then de energize the hold down solenoid L2 insertion solenoid L1 and the shoe horn solenoid L3 The envelope is then driven from the insertion area into the sealer area The next envelope is fed when the lead edge of the envelope pushes the moistener sensor 53 forward the software will increment by a count of 1 for the EIU The envelope then enters the inverter area and finally exits into the stacker The exit sensor S4 will increment the mechanical counter located behind the manual advance knob door by 1 This sequence is shown in flow chart form on the following page 50173333 DI380 DI425 SI3300 S13500 Service Manual 3 Theory of Operation Envelope Motor M9 ON Sheet Feeder Motor M1 Y Sheet Feeder Motor M2 Y Insert Pre Feed Motor M3 Sheet Feeder Sheet Feeder Envelope Sensor S1 Y In
97. sed a single sheet is fed into the paper path and driven into fold plate 1 When the sheet reaches the deflector stop the paper is buckled This buckled edge is then pulled through fold rollers 2 and 3 which creates the first fold It then enters fold plate 2 until it reaches the deflector stop where the sheet is buckled again The edge is pulled into fold rollers 3 and 4 creating the second fold At this stage if an insert is programmed as part of the job the insert will fired into the waiting document The envelopes are fed flaps up and trailing through the flapper unit where the envelope flap is peeled away from the body of the envelope The envelope then passes through to the Q station area where it is stopped The flap of the envelope is held back by the brush The envelope is opened when the flipper fingers press down on the back of the envelope and four insertion fingers enter the envelope throat The folded sheet package at fold rollers 3 and 4 travels through the transport plate rollers and is driven into the waiting envelope by the insert drive rollers Once the insert fully enters the envelope the Q station fingers lift up and the package then travels along to the sealer rollers where moisture is applied to the envelope flap The body of the envelope is forced up into the inverter stop this in turns forces the envelope back into the nip of the sealer rollers and presses the flap against the body of the envelope The envelope ac
98. sert Feeder DDD 3 Sensor DDD 1 Sensor DDD 2 Sensor ON LII Lead 52 Insert Motor Del Collation Motor M5 Fold Plate 2 Sensor OP14 Hold Down Solenoid 2 ON Insertion Solenoid L1 Shoe Horn Solenoid Transport Pivot L3 ON Unblocked Blocked Sensor OP5 Finger Solenoid L4 ON Sealer Solenoid L5 ON Hold Down Solenoid L2 OFF Insertion Solenoid L1 OFF SOFTWARE TRIGGER Shoe Horn Solenoid L3 OFF Moistener Sensor S PAPER PATH oftware Counter S3 Exit Sensor Mechanical Item Counter S4 EXIT Flow Diagram Two Sheet Feeders Plus an Insert Mode 5013333 DI380 DI425 SI3300 S13500 Service Manual 3 11 3 Theory of Operation 3 7 3 12 THE FOLD ONLY MODE When the start button is pressed the sheet feeder motor M1 is switched on This feeds a sheet over the Double Document Detector 0001 sensor The sheet stops after a counted delay in the collation nip This results in the sheet being slightly over driven The software disables the envelope motor M9 and envelope sensor S1 and sends the signal to turn on the collation motor M5 The next sheet fed from the sheet feeder will be triggered by the previous sheet fed entering the fold plate 2 sensor OP14 When the folded sheet enters onto the pivot plate this moves the flag out of sensor OP5 The
99. shoe horn solenoid L3 The envelope is then driven from the insertion area into the sealer area The next envelope is fed when the lead edge of the envelope pushes the moistener sensor S3 forward the software will increment by a count of 1 for the EIU The envelope then enters the inverter area and finally exits into the stacker The exit sensor S4 will increment the mechanical counter located behind the manual advance knob door by 1 This sequence is shown in flow chart form on the following page 50173333 DI380 DI425 SI3300 S13500 Service Manual Insert Pre Feed Motor M3 Y Insert Feeder DDD 3 Sensor Insert Motor M4 Transport Pivot Plate Unblocked Blocked Sensor OP5 SOFTWARE TRIGGER ssi PAPER PATH Flow Diagram Single Sheet Feeder Plus an Insert Mode 5013333 DI380 DI425 SI3300 S13500 Service Manual Sheet Feeder Motor M1 Y Sheet Feeder DDD 1 Sensor Collation Motor M5 Fold Plate 2 Sensor OP14 3 Theory of Operation Envelope Motor M9 ON Envelope Sensor S1 ON Lead Edge Sensor S2 ON Insertion Solenoid L1 Hold Down Solenoid L2 ON Shoe Horn Solenoid L3 ON 1 Finger Solenoid 4 Sealer Solenoid 5 Down Solenoid L2 OFF Insertion Solenoid L1 OFF Shoe Horn Solenoid L3 OFF Moistener Sensor Software Counter S3 Exit Sensor Mechanical Item Counter S4
100. st to the top of the sheet Sheets must be printed in reverse collation order Therefore the last sheet processed in each set is the address sheet which appears in the window of the outer envelope and the first sheet processed is the last of each set Feed Direction Benchmark fixed Safety fixed Not EOC Not BOC Parity Retiming fixed Select Feed 1 Select Feed 2 Auto Batch Retiming fixed if this group is in use Wrap Around Sequence 3 WAS3 Wrap Around Sequence 2 WAS2 Wrap Around Sequence 1 WAS1 Retiming fixed if this group is in use 6 3 2 Z Fold and Single Fold jobs Marks must be placed in the lower right corner of the sheet The marks must be printed in the bot tom to top order The benchmark being the mark closest to the bottom of the sheet Group 1 mandatory Group 2 Group 3 Retiming fixed if this group is in use Wrap Around Sequence 1 WAS1 Wrap Around Sequence 2 WAS2 Wrap Around Sequence 3 WAS3 Retiming fixed if this group is in use Auto Batch Select Feed 2 Select Feed 1 Retiming fixed Parity Not BOC Not EOC Safety fixed Benchmark fixed Group 3 Group 2 Group 1 mandatory Feed Direction V Sheets must be printed in normal collation order Therefore the first sheet processed in each set is the address sheet which appears in the window of the outer envelope and the last sheet processed is the last of each set 50132333 DI380 DI425 SI3300 SI3500 Service
101. t in Use E91 OMR Set Too Large E92 OMR End of Batch Ready to Run E96 Insert Prefeed Roller Stall on Wedge on Last Insert E111 OMR Emergency Stop E113 VPS Disconnected E114 VPS FUII The code does not have an EVEN number of marks The sequence number is not sequential with the previous page fed Sheets are in the wrong order or missing The Selective feed and Autobatch marks at positions 7 to 9 are different to those on the previous sheet of this set A selective feed mark is present at positions 7 to 8 but the job setup does not include select feed The set contains too many sheets from the main feeder This indicates that the machine has stopped for End of Batch Allows the operator to manually sort the envelopes Check side guides separation from pre feed rollers Check RS232 cable is connected to the VPS and inserter Check power cord power off power on Remove mail from the stacker then press start 7 Service Menu amp Troubleshooting Error Codes Operator Check List Service Diagnostic Connector and Replacement and fault Logic Test Parts OMR sensor possibly faulty or needs calibrating OMR sensor possibly faulty or needs calibrating OMR sensor possibly faulty or needs calibrating OMR sensor possibly faulty or needs calibrating OMR sensor possibly faulty or needs calibrating Check wedge is moving freely and that pre feed rollers are in contact with
102. t of 400g m per set can be processed in the Manual Feed Mode Only Sheet Feeder number 1 plus the Insert Feeder if required can be used for Manual Feed applications The maximum compressed thickness after folding should not exceed 2mm Glossy coated sheets are not recommended Fold Type and Overall Thickness Limits The table below shows the maximum number of sheets that can be accumulated or collated for each fold type based on different weights of paper It is important that jobs exceeding these maximums are NOT programmed into the machine or imposed by OMR code printing and or OMR selective feed Temm Paper Weights g m ide 60 80 81 100 101 120 c2 C ZS D 26 EENN o ene 2 5 Fold Types C Z S D 2 8 2 8 C C Fold 075 Single Fold c D Double Fold The sheet limits above can be used with 1 additional sheet from the Supplementary Feeder plus 1 Insert only if the total Mail Piece contents are up to a maximum of 2mm total compressed thickness For SINGLE Fold ONLY using 60 75g m paper ONLY up to 10 items can be placed into an envelope This 10 item maximum INCLUDES any additional sheet from the Supplementary Feeder and or Insert The overall maximum compressed thickness of 2mm still applies 5013333 DI380 DI425 SI3300 S13500 Service Manual 2 1 2 Specifications Insert Feeder Minimum Insert size 127mm Width 82mm Length
103. t plate Test out of paper sensor OP9 Test Daily mail sensor OP3 Test Sheet feeder motor 1 Test Sheet feeder encoder Visually check the separator pad and roller Test DDD sensor levels Test out of paper sensor OP10 Test Sheet feeder motor M2 Test Sheet feeder encoder Visually check the separator pad and roller Test DDD sensor readings 5013333 DI380 DI425 SI3300 S13500 Service Manual P35 pins 2 and 3 P36 pins 9 and 10 P14 pins 1 2 3 P20 pins 19 20 21 P23 pins 1 2 3 P21 pins 1 2 P20 pins 4 5 6 Check for 5096 drop on the display screen P19 pins 12 13 14 P18 pins 1 2 P19 pins 1 2 3 Check for 5096 drop on the display screen Replace sensor 54 Replace sensor 53 5 9 Sensor Motor M1 Encoder Sensor DDD1 Sensor OP10 Motor M2 Encoder Sensor DDD2 E24 Insert feeder not fed to roller E25 Envelope not fed to the insertion area E26 Paper left feeder 1 but did not reach the transport plate E27 paper left feeder 2 but did not reach the transport plate E28 Motor PCB link Failure E30 Sheet feeder 1 removed E31 Sheet feeder 2 removed Remove material from the insert feeder and restart Aerate the material Check side guide set up Check separator and stone settings Open flapper cover and remove any material Check the envelope feed orientation Make sure the flapper unit is properly closed down Remove
104. ted into the envelope After the last document has entered the envelope the pivot plate moves the flag out of the sensor OP5 This operation then triggers the software to energize the finger solenoid L4 lifting the fingers and lifting the brush of the sealer by energizing solenoid L5 and the insertion solenoid L1 The shoe horn at this point stays energized until the package passes the moistener sensor S3 The envelope is driven from the insertion area into the sealer area The next envelope is fed when the lead edge of the envelope pushes the moistener sensor 53 forward the software will be Incremented by a count of 1 for the EIU The envelope then enters the inverter area and finally exits into the stacker The exit sensor S4 will increment the mechanical counter located behind the manual advance knob door by 1 In normal run mode if no material has been detected at the Double Document Detection sensor the sheet feeder motor M1 will time out after approximately 2 seconds This is to clean the separator roller and pad In daily mail manual feed mode this time is increased to approximately 20 seconds for operator loading The manual feed lever opens the gap between the separator roll and pad This sequence is shown in flow chart form on the following page 50173333 DI380 DI425 SI3300 S13500 Service Manual Sheet Feeder Motor M1 OP9 Sheet Feeder 0001 Sensor CD Collation Motor M5
105. tion of all belts Insert Feeder Check clean Separator Roller Check clean Carriage Rollers upper and lower Clean out of paper and carriage complete sensors Lightly lubricate shaft cam with grease Fold Rollers Clean all Fold Rollers you must remove carriage complete assembly side brackets first for easy access Clean fold plate sensors Sheet Feeders Check clean Separator Roller Check clean Separator Pad Check clean Lower Collation Rollers Clean all out of paper and interlock sensors Sealer Change or rotate the felt Check clean Transport Rollers Check clean Sealer Brush Inverter Exit Check clean Sealer Rollers driven and idler Check clean Exit Rollers driven and idler Envelope feed Check clean Separator Pad Check Prefeed Rollers Clean all sensors with a damp cloth or use a brush air duster to remove any surface dust Lightly lubricate the following with grease Manual Advance gear spindles Cam on Insert Envelope Drive Clean bobbins and rollers with Isopropyl Alcohol or equivalent cleaning agent Reassemble machine and test 5013333 DI380 DI425 SI3300 S13500 Service Manual 8 1 8 Preventive Maintenance 8 3 THE 200K SERVICE po 07 de dw 10 11 12 13 14 15 16 17 18 8 2 Check that all material falls within specification Check operation of equipment Check operation of safety interlocks Listen for any unusual noises Visually check for
106. tivates the exit switch as it passes the exit rollers and increments the counter by one 5013333 DI380 DI425 SI3300 S13500 Service Manual 3 1 3 Theory of Operation 3 2 3 2 SINGLE SHEET FEEDER MODE amp LINKED FEEDER MODE When the start button is pressed the sheet feeder motor M1 is switched on This feeds a sheet over the Double Document Detector DDD1 sensor and stops it after a counted delay in the collation nip This results in the sheet being slightly over driven At the same time the envelope motor M9 is switched on and an envelope is fed through the separator pad and roller When the lead edge of the envelope moves forward to the envelope sensor S1 the software sends the signal to turn on the collation motor M5 The transported envelope stops in the insertion area at a predetermined time according to the size of envelope programmed within the job setup The insertion solenoid L1 energizes followed by the hold down solenoid L2 and finally by the shoe horn solenoid L3 The next sheet fed from the sheet feeder is triggered by the previous sheet fed entering the fold plate 2 sensor OP14 When the folded sheet enters onto the pivot plate this moves the flag out of sensor OP5 When the folded sheet is fully inserted the pivot plate moves backwards returning the flag to its home position This operation triggers the software to energize the finger solenoid L4 lifting the fingers and lifting the brush o
107. tor pad and roller Clean Replace the separator pad and roller Clean Replace the separator pad roller and pre feed roller Clean Replace separator pad and roller Change DDD Clean Replace separator pad and roller Change DDD Clean Replace separator pad and roller Change DDD 11 7 Service Menu amp Troubleshooting Error Codes Operator Check List Service Diagnostic Connector and Replacement and fault Logic Test Parts E19 Material never entered and or left the exit sensor E20 Material never entered and or left the moistener sensor E21 Material never released from the transport plate E22 Sheet feeder 1 not fed to collation roller E23 Sheet feeder 2 not fed to collation roller 12 Open inverter door and remove any material Open moistener sensor cover and remove any material Check job set up Fold panels and envelope depth Adjust the side guides Remove material from insertion area Check job set up Remove material from sheet feeder 1 and restart Aerate the material Check the side guide adjustment Open the top cover open jam access cover and check for any material Check job set up Remove material from sheet feeder 2 and restart Aerate the material Check the side guide adjustment Open the top cover open jam access cover and check for any material Test exit sensor S4 Test moistener sensor S3 Test sensor OP5 Check for free movement of the transport pivo
108. ts in a 22mm window There are 7 High and 7 Low From these readings the software will take 7 relevant readings The sensor is positioned 50mm to the left of the centre line the LEAD position the double detection will start reading at approximately 22mm from the lead edge of the document in the direction of feed When a double is detected the machine will stop and the document will be in the collation nip area The machine will indicate which feeder the double has been fed from on the control panel On the MIDDLE position not available on the insert feeder the double detection will start halfway down the document This is taken from the length of paper entered in the Job Set Up Menu When a double is detected the machine will stop and the document will be in the insertion area The machine will indicate which feeder the double has been fed from on the control panel On the TRAIL position not available on the insert feeder the double detection will start approximately 45mm from the trail edge of the document in the direction of feed This is taken from the length of paper entered in the Job Set Up Menu When a double is detected the machine will stop with the document inserted and fed into the stacker area The machine will display Double Check Stacker and also indicate which feeder the double was fed from on the control panel centre line centre line DDD Scan Areas 3 16 50173333 DI380 DI
109. tting Continued 5013333 DI380 DI425 SI3300 S13500 Service Manual 5 11 5 Adjustments 3 Set Stone to position DI380 S13300 01425 513500 Separator Stone Setting 4 Loosen the allen screw locking the Separator Thumbwheel 4 Insert a sheet of 80 g m paper under the Separator Rollers Adjust the Separator Knob until you feel a slight drag on the paper without scoring 5 Retighten allen screw Separator Thumbwheel 3 2 E d 3 4 Insert Feeder Separator Roller Height Adjustment 5 12 5013333 DI380 DI425 SI3300 S13500 Service Manual 5 Adjustments 5 13 3 Separator Pre Feed Height DI380 813300 Only 1 Move the Detent setting to the middle position 5 setting Middle Position Detent Setting 2 Loosen adjusting screw A until the Pre Feed Rollers fall and touch the deck 3 Turn knob B fully open using A Separator Pre Feed Adjustment Points 4 allen screw A until there is a gap of between 11mm and 14mm between the Insert Feeder Side Guides and the Pre Feed Roller 5 Reassemble the Insert Feeder Separator Pre Feed Adjustment Note sure there is no interference with the side guides and the pre feed rollers when you set the insert feeder to the minimum insert width 5013333 DI380 DI425 SI3300 S13500 Service Manual 5 13 5 Adjustments
110. ultiple Page Document Benchmark fixed Safety fixed First Page of Set Not EOC Last Page Fed Not BOC Parity Re timing fixed Benchmark fixed Safety fixed Middle Page s Not EOC Not BOC Parity Re timing fixed Benchmark fixed Safety fixed Last Page of Set Not EOC First Page Fed Not BOC Parity Re timing fixed Allowable mark combinations for Basic OMR SDT3233A DI380 DI425 SI3300 S13500 Service Manual 6 9 6 6 11 6 12 6 13 6 14 6 10 Enhanced allows you to stop feeding sheets at selected points a run and or to select whether the other feeders are used separately for each envelope It also provides a higher level of mailpiece integrity so that sensitive documents are not sent to the wrong customer AUTO BATCH Enhanced OMR adds an Auto Batch mode to supplement the normal OMR batch mode This can be used to stop the OMR at predefined points in the run for example between addresses with different post codes at tray breaks or to identify pieces for special handling such as a hand signature An OMR mark derived from the print database specifies whether or not to stop the run after completion of the current set This mark if printed must be present on all sheets within that set For Auto Batch mode use Group 1 and Group 2 marks and optionally Group 3 SELECTIVE INSERTION Selective Insertion allows you to specify whether to include a s
111. upplementary sheet from the other sheet feeder using Select Feed Mark 1 or if the set is to include an item from the insert feeder such as a card business reply envelope or folded insert Select Feed Mark 2 must be printed If Select Feed 1 Mark is printed the supplementary sheet will be folded with the first sheet of the prime set and if Select Feed Mark 2 is printed a folded insert will be nested with it When using Select Feed the mark s must be printed on all of prime sheets with in the relevant set Limits on paper dimensions and weights remain as currently specified for the OMR in Section 2 the Specifications section of this manual For Selective Insertion use Group 1 and Group 2 marks and optionally Group 3 WRAP AROUND SEQUENCE A series of three OMR marks can be used to implement a sequential count across a print run These wrap around sequence marks ensure a higher level of integrity by counting in a binary sequence sheet by sheet in order to detect missing or misplaced sheets If the OMR detects a break in the se quence non consecutive marks it stops and displays an error message For example the inserter would stop if the printer had picked up two sheets when printing a page or if the pages have been disturbed and are out of order or if the OMR picks up two sheets while its double detect feature is not in use So that a run can be restarted at any suitable point the OMR assumes that the first sheet it picks up on start
112. ustments 20 5 11 5 13 5 13 1 Separator Roller Alignment 5 11 9 19 2 Roller Height 5 11 5 12 5 13 3 Separator Pre Feed Height 01380 51330 Only 5 13 5 14 Skew Adjustment 5 14 5 15 Flapper Adjustment 5 15 6 6 1 Brief Overview of OMR on this system 6 1 6 2 OMR Specifications 6 2 6 6 Standard OMR Positions Diagram 6 3 Offset Positions 6 4 Offset OMR Positions 6 5 6 3 OMR Mark Grouping Wer 6 7 6 3 1 C Fold and Double Fold Jobs 6 7 6 3 2 2 Fold and Single Fold Jobs 6 7 6 4 Basic OMR 6 8 6 5 6 8 6 6 6 8 ii SDT335A MMI Service Manual amp Parts List Contents 6 7 BOC NOT AND 6 8 6 8 Parity and Other Checks ede 6 8 6 9 Retime Marks I mI 6 9 6 10 Allowable Mark Combinations 6 9 6 11 Enhanced 6 10 6 12 6 10 6 13 Selective Insertion 6 10 6 14 Wrap Around Sequence 2 c Ro 6 10 6 15 Wrap Around Se
113. velope Check envelope feeder is not over filled Re start machine Re start machine Check Sensor is centred over the OMR marks Wipe sensor to remove dust Ensure paper is loaded correctly into feeder Power machine on off Check Sensor is centred over the OMR marks Wipe sensor to remove dust Ensure paper is loaded correctly into feeder Power machine on off Code type on paper does not match the setup Example setup has OMR Sequence but paper has Select Feed Sequence A re timing scan mark is missing Check material Example mark 6 is missing from a 10 mark code The BOC mark position 4 was present when it was not expected First page of the set was expected The BOC mark position 4 was absent when it was expected Pages other than the first page of the set were expected Check envelope platform upper limit switch IL 13 and envelope present sensor P511 OMR sensor possibly faulty or needs calibrating Loss of drive OMR sensor possibly faulty or needs calibrating Check configeration of OMR marks Possibly using Swiss Offset or offset position OMR sensor possibly faulty or needs calibrating OMR sensor possibly faulty or needs calibrating OMR sensor possibly faulty or needs calibrating 18 5013333 DI380 DI425 SI3300 S13500 Service Manual E87 OMR Parity Error E88 OMR Sequence Error E89 OMR SF Marks Inconsistent E90 OMR SF No
114. vity of the OMR scanning sensors on Sheet Feeders 1 and 2 as they are adjusted on the Production line Should the customer s application change whereby the material colour changes or the scanner appears not to function correctly then it will be necessary to perform the sensitivity adjustment The set up sheet form number SDT316 is required when making this adjustment A reduced size reproduction of this sheet is shown in item 6 11 on page 6 17 of this document Scanner MUST be positioned correctly over the centre of the scan dash marks Procedure Press Set Up key under the control panel Enter 61 and press the Next key Select either Sheet Feeder 1 or 2 using the Next key Display will show Set Sensitivity Sheet 1 or 2 as selected Press the Start key Using the Next key select Manual OMR Set up Sheet 1 or 2 as selected Press the Start key Display will show Load Blank Sheet START For Sheet Feeder 1 place a BLANK sheet of paper under the set up sheet Manually advance the set up sheet until the Blank box is under the sensor Press the Start key Display will show Load Marked Sheet START 10 The sensor light output will pulse slowly in Red Now manually advance the set up sheet until the grey hatched area is under the sensor 11 Press the Start key 12 The sensor light output will now be permanent steady in either Blue Red or Green depending upon the paper colour and ink type Normally for black OMR marks on a wh

7 • Service Menu & Troubleshooting

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7 &bull; Service Menu &amp; Troubleshooting

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7 • Service Menu & Troubleshooting