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438A Folder / 438B Feeder V4 Service Manual

1. ay EE 4 Pd th At T mmm m Fein 4 4n mp i m m m Hess N Lu 1 Ww 2 Parts List 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 3 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 4 C 2 DC POWER DISTRIBUTION CHASSIS Power Supply Ass y 044 31500 500 To Open Chassis Use enclosure The 24vdc supply is used to power the input output modules on the relay opto racks and to power clutches brakes and sensors and E Stop amp interlock circuits The 5vdc supply is used to power the reader backplane reader encoder CPU and other digital circuits Above is the DC Power Distribution enclosure that contains a 24vdC a 5 12 12vdc power supplies The E Stop and Interlock board is also enclosed at the top of this enclosure and ower Supply 12 amp 12 DC Power Distribution Bd gt 042 31350 500 IP TEL uep wass Power Supply 24vdc j EL o2 2008 12463 Y EA 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 5 438 OPERATOR amp SERV
2. i 00 D SS ow gt u gt a x a 24V RET 24VDC M BR SYSTEMS CORPORATION 72 299 12 INSPIRATIUN LANE CHESTER 06412 UNLESS OTHERWISE SPEC 860 526 9 S ARE IN INCHES TEL 860 526 9561 e n TDLER NEXT ASSY USED ON t 00 RANCE ANGLES 2 ORIGINAL APPLICATION T NNECT RACK PURT o DRAWN E HARRIS 2 7 2006 REMOVE BURRS SHARP EDGES amp CORNERS THIRD ANGLE PROJECTION aes SIZE DwG ND 1 597 31570 3 SCALE SHEET OF d 1 1 UR TH SMITTED TO ANY N WITHOUT WRITTEN PORATION 01 ee a INTERPRET DRAWING PER ANSI Y14 5 8 315 10 310 3LK RED RED BIK FEEDER CLUTCH TACH JBL DETECT SENSOR FEED SENSOR an INTERLOCK REVISIONS DESCRIPTION APPROVED
3. N AN C i 2 Cr V ke 3 2 3 2 QE D aN Shy T 6 A C 23 HA A 24 zi 24 A TO Iu bu d KY Iu L A 1 JO A 2 Ko WE C L rA k N 8 lan lan 2D A V JA O 2 L 16 A p MATL SE Veo N GBR SYSTEMS CORPORATION NSH 2 ba D N AN ALS Esa F gt INSPIRATION LANE CHESTER CT 06412 UNLESS OTHERWISE SPECIFIED 438B ey L 860 526 95t x ESSA TEL 860 526 9561 DMENS RE IN INCHES NEXT ASSY JSED ON AND 005 TOLERANCE SEXE TTE ANGLES 2 ORIGINAL APPLICATION SC 2 BACK AN R DRAWN E HARRIS 006 x I REMDVE B FLECT EDGES amp CHECKED DJEC BENE SUE DWG ND 3 c Sq ES yn eee 2 042 31549 300 x SCALE SHEET OF INTERPRET DRAWING PER ANSI Y14 5 l 4 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 ELECTRONICS SECTION C PAGE 19 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 20 SH B U 042 31350 300 REVISIONS ZONE REV DESCRIPTION DATE APPROVED ORIGINAL RELEASE ECN 9394 08 15 06 E JH N Y Y s si N N o o e gt gt a gt
4. INSERTER INTERF Pa A MATL S Oe A EET GBR SYSTEMS CORPORATION 12 INSPIRATION LANE CT 0641 ESS OTHERWISE IS TEL IONS ARE IN 1 RES ROSE NEXT ASS TOLERAN ORIGINAL APPLICATION THE Pm E HARRIS 27 ERTER MODULE 7 438 V4 ELECT REMOVE BURRS xem EDGES amp CURNERS CREE THIR LE PROJECTION SUE DWG ND Re a THIS DRAWING IS THE PROPERTY GBR SYSTEMS Y es MC RATION IT IS RETURNABLE U es 5 vs N 1 0 dla 7 PRODUCED Di HE INFO N TRANSMITTED TO ANY L b DN WITHOUT WRITTEN CONSENT SCALE 4 4 SHEET 4 INTERPRET DRAWING PER ANSI Y14 5 FROM GBR SYSTEMS CORPORATION 1d 1 ISSUE 2008 05 ELECTRONICS SECTION C PAGE 41 438 OPERATOR amp SERVICE MANUAL 071 28558 401 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 ELECTRONICS SECTION C PAGE 42 SIZE DWG N REVISIONS DESCRIPTION DATE APPROVED ORIGINAL SELEASE E CN 9394 08 15
5. K 0 INTERLOCK RED N Y CUTIER EXT FEEDER STITCHER AU INSERTER 4 A sl Q 35 1 lt x eod x E IE e 12 ad L ER RED s JUMPER JUMPER AIA JUMPER 15 WT JUMPER JUMPER PE JUMPER JUMPER BLK WHT m G 7 SARE L YI BLU KEYB T r BRN L le YEL I5 VO Te lt T D C S MATL FNSH GBR DMENSION AND ANGLES REMOVE BURRS SHARP EDGES amp CORNERS UNLESS OTHERWISE SPECIFIED 438B NCHES NEXT ASSY USED ON CE 12 INSPIRATION SYSTEMS ANE CO CH TEL 860 52 RPORATION ESTER CT 06 ORIGINAL APPLICATION DRAWN E HARRIS INTERPRET THIRD ANGLE PROJECTION PER ANSI Yl45 gt ES amp INTER P 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 ELECTRONICS SECTION C PAGE 29 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 30 SIZE DWG NO co SH 3 397 315 0 305 S R
6. 12 C 9 LINE CODE READ CHASSI S 13 C 10 INK MARKER CONTROL BOARD 15 C 11 CREEPER CONVEYOR MOTOR CONTROLLER 16 C 12 FEEDER MOTOR CONTROLLER 17 C 13 ELECTRONICS SCHEMA TTICS 18 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 1 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 2 C 1 LEFT SIDE VIEW MAIN CABINET ELECTRONICS CABINET ASS Y 005 28579 501 pi C m Sa e ITEM C 1 RIGHT SIDE VIEW MAIN CABINET ELECTRONICS CABINET ASS Y 005 28579 501
7. 4j SIZE lt C 597 31570 319 gt 046 30408 000 N TE TINNI Y Y X Y Y Y Y Y YI REVISIONS DESCRIPTION APPROVED ORIGINAL RELEASE ECN EJH IPUTER FREI LINE C READ ITH ONLY ONE RE ND CONNECT C BLK MATL FNSH S ARE IN ANGLES Xe REMOVE B EDGES TOLERANCE WS SHARP RNERS UNLESS OTHERWISE SPECIFIED 438B VENSION HES ES NEXT ASSY USED ON ORIGINAL APPLICATION DRAWN E HARRIS 2 7 2001 HECKED THIRD SE JECTIUN INTERPRET DRAWING PER ANSI Y14 5 11 t
8. SIZE PORT UM TIPP T z a u 3 3 3 3 3 LAMP MMMM TAUT q AAAA T WWE 30ARD REVISIONS DESCRIPTION APPROVED ORIGINAL RELEASE ECN 9394 EJH I sl z FEEDEI T j gt 21 D xi le og IZ 1 a al Le se zu 22 Em gt l al 1 I Lx _ ese i lt lt EXIT B PX CONVEYOR d eye 21 pP Fx l l 2 Cl zi El PP cu an 51 sal pe B 4 e EE iul Ld 1 d PI fe lt INSERTER Wer wel Le get zem pne S Fx be el I xz CUTTER e le lt bowel ENT pr gt Tep xi 1 1 al I 1 T m z 195 ERE SHE jl lt el 2 T wS I s 1 1 12 INSPIRATION 438B NEXT ASSY USED ON IB SYSTEMS TEL 860 LANE 32 6 95 HESTER CT ol ORIGINAL APPLICATION DRAWN HARRIS gf CHEC
9. DRAWN E HARRIS CHECKED G IS THE PROPERTY OF GBR SYSTEMS B Ju k 3 319 m j J 21 27 UTS u D 1 D 2 D 3 SECTION D PROBLEM ANALYSIS GENERAL SOLUTIONS TO ERRORS 2 INITIAL ACTIONS 4 UNDERSTANDING CARD ID AND SCHEMATICS Error Bookmark not defined D 4 D 4a D 4b D 5 D 5a D 5b D 5c D 6 D 6a D 6b D 6c D 6d D 6e D 6f D 6g D 6h D 6i D 6j D 7 D 7a D 7b 438 OPERATOR amp SERVICE MANUAL TEST SCREEN OPERATION 5 Speed Test ore C EH ERI RR ERE 5 Test Gycle au asun m OI REN ER PR HE RE 5 IO 144 Board Inputs and Outputs 6 Ori ntatiOTi cR Pn TUI I d REI 6 Locating I O LED s Card Components 6 VO Reference Charts 20228 iet eoi ttti oni d usd 7 ERROR CODES 10 11xxx SySt m meter er tee n eene 11 12xxx Peed E oU Un Rte 12 13xxx Accumul tor a eter tret tetro 14 su iuo 14 15xxx Xfer Conveyor Xfer Cvyr 15 l6xxx or 18xxx Reader eee eret 17 17xxx Inserter Error Messages eee 26 19xxx EngValue Error Messages sese 26 20xxx EXITCOMM Error Messages 26 21xxx InFeed Error Messages eee 26 ANALYSIS 27 Troubleshooting the GBR Line Code Reader
10. 27 Physical Specifications of the Line Code System 27 071 28558 401 V4 ELECTRONICS ISSUE 2008 05 PROBLEM ANALYSIS SECTION D PAGE 1 438 OPERATOR amp SERVICE MANUAL 071 28558 401 D 1 GENERAL SOLUTIONS TO ERRORS Many error codes are the result of jammed paper physical errors or paper expected at specific time and location read errors sequence blank page misprinted code etc The sensors index the number of sheets as they pass incrementing a count on the CPU 586 If a corresponding decrement of count does not occur from the next sensor a read error is generated If error persists consider failure of sensor or communication problem poor connection etc For many read errors check that setup parameters are correct before pursuing functional troubleshooting Read errors require a determination of the integrity of the pack The operator must look at the readings on the display and manually verify each sheet When read errors occur it indicates the integrity of the package is in question The 438 was not able to verify a page while stream feeding a package When the operator is satisfied the package is complete press the DUMP key to release the package Once a reading error BLANK or MISREAD is declared additional feeding via the CYCLE key will continue to display BLANK or MISREAD errors but will not stop the machine ISSUE 2008 05 PROBLEM ANALYSIS SECTION D PAGE2
11. EDGES amp SIZE DWG NO i AUTHORIZED SCALE SHEET OF N CONSEN SCALE id l INTERPRET DRAWING PER ANSI Y14 5 a 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 39 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 40 SIZE lt DWG ND SH REVISIDNS ZUNE REV DESCRIPTION DATE APPROVED ORIGINAL RELEASE ECN 08 15 06 EJH BLK BLK 81 1 FLATS wat BLU BLK 2 OLLEC CRN RED RED WI AA RED RED RED RED INTERLI INTERLI FOLDER T FOLDER EXIT SEN lt 8 8 lt a S8C lt lt lt COLLECTOR t 10 lt lt EXIT m AK 8 m 5 1 pNK 1 PNK E lt 11 S 2 TAN 12 e 19 Li L2 BK KA i RED GRN 11 NEL 12 BLK MODULE 6 O S RED YEL RED YEL AED NEL JRN e e x E Sabi ES S ml cz c6 amp 14 14 lt BLK a RED BLK EE v BLU S om om WHT BUK RED BLK lt 15 RED BLK ET RED WHT RED WHT BLK n I BLK BLU
12. RELEASE ECN 9394 EJH MATL d FNSH UNLESS OTHERWISE SPEC DMENSIONS ARE IN AND ANGLES 2 REMOVE BURRS SHARP EDGES amp C CHES TOLERANCE 438B CAL I USED DN GBR 12 INSPIRATION RPORATION CT 06412 L APPLICATION DRAWN E HARRIS 2 7 2006 CHECKED THIRD ANGLE SAN APVL UN THIS DRAWING 15 THE PROPERTY OF CORPORATION IT IS RETURNABLE UPON 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 ELECTRONICS SECTION C PAGE 35 view 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 36 B 597 31570 311 j REVISIONS ZUNE REV DESCRIPTION DATE APPROVED ORIGINAL RELEASE ECN 9394 08 15 06 EJH 4 FEEDER 2 40 9 3LK iu RED H d HI WHT 6 CRI ORG i L lt Bu M _ 2 BEN mE 7 A
13. A Shh ve x 1 FOLDER SIDE 0 PLATE GROUND a 21 N GRN YEL BLK LINE FILTER d d x z e m 5 TBI P P P c n 8 gt D d e A G A 2 e eo k e e 2 ay a a EN ay A a a at m EI i5 a x E e tu o ul d e v z o m 5 cw B oO z 4 x I I oc NI x x x ES x FA A Al if m a eie U J 11 E x x I n m m amp 3 3 zd m Y Th N x p SORPORATI HESTER REFER TO THE OPERATC NEXT ASSY USED ORIGINAL APPLICATION THLE FOLDE REMOVE BURRS SHARP CHECKED EDGES amp CORNERS GLE PROJECTION SIVE DWG ND NFORMATION PERSON FROM GBR SYSTI oF 1d l INTESPRET WING PER ANSI Yl4 5 SIZE DWG ND ma Ty SH H B
14. a E m Lu 5 Qm o eOu un00mtwY o0oxuulH Y u a gt A Oo o u gt Sr id Z x x a gt x a 2 x ax z AD Si eae 5a 5 x z u Qu 0 x c OX D Qu ip 0 E 000 won 0 00 x wor OR ODO iD 0 0 O IN AN AN AN AN INN IN AN AN IN UN IN INN UN AN AN IN IN AN AN AN AN IN AN IN IN N l A NV V V V V V V V WV V V NE NV V V V V V V V V N V V V V V VV V V V V V V V V V V V V N V V V V V MOOD o ID om OD V 0 m v c O O O O gt OF 0 oro Or O i gt SSS Ke E gt gt 200725 Y gt Y gt gt ou o 23 lt ou 4 Qu _ do x 1 3 ua sa 4 gt ua po gt uu d T u gt u a gt a Qu FU ao s x e Tc au io x 5 a 80 uox o Y s 4 YN Q D Ss 0 Q MAT
15. 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 ELECTRONICS SECTION C PAGE 43 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 44 SIZE DwG ND z 7 6 ny SH 597 31570 319 REVISIUNS ZONE REV DESCRIPTION DATE APPROVED ORIGINAL RELEASE 9394 08 15 06 E JH Sos 5V DC A gt SVCOM VI Q 1 F gt 2 gt gt 5 gt 12VDC gt 1 gt gt 42 12 INTERFACE Le lt BRD T ESO 250 042 30445 8 EN iB E a gt j un ENCODERES 4 u eo ENCODER gt 1 7 GBR SYSTEMS CORPORATION d x 12 INSPIRATION LANE CHESTER CT 06412 UNLESS OTHERWISE SPECIFIED 438B E ume a DMENSTONS ARE SIN T NEXT ASSY USED ON AND 005 TOLERANCE ANGLES 2 ORIGINAL APPLICATION TIPE
16. Exit Comm No Message Response 20801 0 Default Utilizes poling method for input See EV 36 for time setting If set to 0 no retries are 1 Utilizes interrupt method for input initiated and if an Ack Response is not received in the 44 1 Accum Pack Bad Set Pack After Bad Also allotted time EV 36 an error is generated Range 0 gt 1 Inc 1 Default 1 1 Default Upon occurrence of a bad pack the next 38 2 Barcode Reader 1 AS 30 2 MS911 3 DL2031 pack processed is tagged as bad also until a good pack is processed Bange d 3 met 0 Next pack if no error in normal processing is not Default 2 Will select the Start and Stop protocol for lagi ad uda bad acit p 9 either an Accusort Model 30 or a microscan 5911 99 PE 1 Accusort Model 30 Bar Read Start Serial Trigger 45 1 Accum Pack has Single Set Pack Bad Range 0 gt S Bar Read End Serial Trigger E 1 Inc 1 Default 1 2 Default Microscan MS911 Bar Read Start Serial 1 Default Upon a single cycle accumulation of a pack Trigger lt S gt Bar Read End Serial Trigger lt J gt in the accumulator the pack processed is tagged as 3 DataLogic 2031 Bar Read Start Serial Trigger S bad Bar Read End Serial Trigger E 0 pack is not tagged as a bad pack 39 0 Bad pack Retain Selects 1 Yes 0 no Range 0 gt 1 Inc 1 Default 0 0 Default Normal operation Upon Bad Pack select and e
17. 24 250 Feed to Accum Time Range 0 gt 5000 Inc 10 Inc 5 Default 170 170 msec for the lead edge of paper fed at Default 100 Time in milliseconds for conveyor table the feed sensor to the lead edge entering the ON time for each pack out of folder accumulator Range 0 to 5000 msec F 33 2 Number of Double Detect Sample Counts Range 25 1 Advance Feed Switch Range 0 gt 1 Inc 1 1 gt 4 Inc 1 1 ON allows the next pack to be started when the Default 2 Number of Double Detect Sample Counts Accumulator is supposed to dump plus the Accumulator per sheet fed 20msec sample rate Dump Time O OFF starts the next pack after 34 0 This EV intentionally left blank Range 0 gt 1 Inc Accumulator Presence Sensor is cleared plus the Accumulator Dump Time When EV 25 is set to 1 EV s 1 2 23 24 should be adjusted as close to numbers on the right of gt to obtain optimal performance These values may vary depending on type and weight of paper being processed environmental conditions and system tolerances 1 Maximum Sheets Allowed to Accumulate moved to Accumulator Setup in version 26412 051 438 V4 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 INTRODUCTION SECTION A PAGE 29 Number Value Description Number Value Description 35 80 Feed Control Brake Delay Time Range
18. Before powering up the 438 the operator must remove any packages in the accumulator to be sure there will be no initial error conditions For electrical type problems always check the on off switches as they are also circuit breakers There are LED s on the board that the Input Output modules are plugged into that will help isolate many problems refer to the I O 96 Board description in Section D 5 Solutions to Less Common Errors A rare but more difficult to find problem can occur with shorts in the 24VDC circuit Intermittent failure of sensors BVDC supply can result from the 24VDC short The short will only occur when a 24V component activates dropping the 5V supply across the line The 24V solenoid may be located some distance from the sensor which is the apparent problem consider what is supposed to happen before or when the sensor sees the paper If either the Feeder speed or Folder speed are approximately half of the other an encoder channel is probably lost Check speeds through Test menu on display Any time a new CPU 586 board is installed the presets must be reset or there will be an error displayed If PWB errors occur errors with PWB as probable source pull the board and make sure that all board components are properly seated Re install the board and make sure it is properly seated If reader problems are recurring re calibrate with the calibration sheet Feed the sheet through several times to ensure that
19. Check read setup again particularly focus Check for correct feed speed Check speed sensor for proper operation Check for failure on the CPU replace as necessary Bad UARTs Bad software The page that was just fed did not follow the selected page sequencing pattern If the page is not out of sequence check to see that the proper barcode is printed on the page and that the barcode matches the specifications Check to see that the proper barcode job is selected Group is not part of set Check to see that the proper barcode is printed on the page and that the barcode matches the specifications Check to see that the proper barcode job is selected Check read setup again particularly focus Check for correct feed speed Check speed sensor for proper operation Check for failure on the CPU replace as necessary Bad UARTs Bad software 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 REPAIR INFORMATION 071 28558 401 SECTION D PAGE 19 438 OPERATOR amp SERVICE MANUAL 071 28558 401 nn008 nn009 nn010 nn011 nn012 nn013 nn014 nn015 nn016 nn017 EXPECTED PAGE ONE GROUP NUMBER OUT OF RANGE PAGE OUT OF RANGE INVALID NOT ENOUGH NV RAM PRESETS CORRUPT NV RAM FAILED DUAL PORT RAM FAILED INVALID COMMAND INVALID PIC INT ISSUE 2008 05 REPAIR INFORMATION SECTION D PAGE 20 If page sequencing up the software expects the first page of each set
20. N gt BLK r 1 E STOP ncn RED DEF 10 TR S E STOP 2 19 GRN N 4 X 4 NV IN MATL H ZSsssssszssssssesssssa S SYSTEMS CORPORATION FNSH r 12 INSPIRATION LANE CHESTER CT 06412 UNLESS OTHERWISE SPECIFIED 438B TEL 860 526 9561 DMENSIDNS ARE IN INCHES USES 860 526 9561 AND TOLERANCE asas AWGEES Pos ORIGINAL APPLICATION DRAWN E HARRIS 2 7 2006 KEYBOARD MODULE 5 438 V4 ELECT REMOVE BURRS SHARP EDGES amp CORNE THIRD ANGLE PROJECTION VL SVE DWG NU LIN S j 7 INTERPRET DRAWING PER ANSI 14 5 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 37 ISSUE 2008 05 ELECTRONICS 438 OPERATOR amp SERVICE MANUAL SECTION C PAGE 38 071 28558 401 SH SIZE p 597 215 702313 EN REVISIONS gt TION DATE APPROVED JESCRI 08 15 06 E JH 5 ORIGINAL RELEASE EC zi L RED 17 BRN lt A c gt CRN YEL PE 5 x x 5 x m oF E c r GRN YEL
21. REV DESCRIPTION DATE APPROVED z ORIGINAL RELEASE ECN 9394 08 15 06 E JH 502 514 5 500 1 LINE FILTER LI POWER IN O ee 2 c5 N U N LK 3RN 3RN BLK BLK d S 1 1 1 e e e gt lt Sa M s 2 S gt P om mist m me amp SS LM C xa C JX d N FS L N AN L N cal A W JN N EX A A A A A AN 4 2 3 2 3 2 6 5 1 2 3 2 3 P s S AUX AC JC POWER FEEDER CREEPER FLATS FOLDER OPTIONAL OPTIONAL OPTIONAL SUPPLY Et E eg RESER RESERVED o 2 DISTRIBUTION CHASS CONTROL MATL ES GBR SYSTEMS CORPORATION Biss d 24 12 INSPIRATION LANE CHESTER CT 06412 UNLESS OTHERWISE SPECIFIED 438B E j TEL 860 526 9561 JSED ON ORIGINAL APPLICATION AT gt A DRAWN E HARRIS 2 7 2006 M E ARE IN INCHES NEXT ASSY DISTRIBUTI IQ A EDGES amp CORNERS REMOVE BURRS SHARP CHECKED CHASSIS 438 m THIRD ANGLE PROJECTION GO 5465726 AND IS ROPER
22. 0 gt 160 40 1 Electronics 1 New 0 Old Range 0 gt 1 Inc Inc 10 1 Default 1 Default 130 msec Allows the page trail to leave the 1 Default Enables configuration for new modular singulator before the feed brake is applied Delay electronics calculation based on sheet length speed and this 0 Enables I O for classic 420 two rack electronics sas sas 41 0 Sequential Stop Cycles 0 Off Range 0 gt 99 36 100 Exit Comm Recvd Ack Time Range 0 gt 500 Inc Inc 1 Default 0 10 0 Default Normal operation Default 100msec In Tampa 1 only if no Ack 1 99 Demand cycles after package leaves transfer Response is received the machine errors out and resets conveyor that I O point 0 16 Inserter Stop is asserted the comm To try transmit again See EV 37 for upon the occurrence of a Sequential Stop command 42 70 pages track 1 200 Range 1 gt 200 Inc 1 Default 70 37 0 Exit comm Xmit Retries Range 0 gt 2 Inc 1 Used with Flat Feeder configuration Limits maximum 1 Default In Tampa 1 only if no Ack Response is pages that can be accumulated in a track section received defined in EV 36 a retry is initiated and sends a duplicate serial string A range of 0 22 retries can be 43 0 Feed Sensor interrupt 1 ON 0 OFF Range 0 gt indicated before the machine stops and displays the 1 Inc 1 Default 0 error
23. 3 3 16 Important for reinstallation removed in step 5 9 Remove C clip from bearing housing Remove bearing and 14 Replace ball bearing in housing that was removed in step 4 spacer with new ball bearing 186 03112035 Slide onto shaft Note 10 Place spacer back in bearing housing Replace ball bearing location of flat toward infeed end Mount bearing housing with new 186 031112035 inside bearing housing Reinstall with the flange to the right side C clip 15 Tighten down both bearing housings screws 11 Slide complete housing onto new top shaft 186 032017499 16 Install new key 186 031135001 into shaft and replace flat Note turned down side Slide on small spacer 312 Install belt pulley and long spacer that were removed in step 3 new key 186 031135001 timing pulley 2 long spacers washer and screw will be loctited at a later step 17 Apply blue loctite 188 24205 onto screw threads on both ends of shaft Tighten both screws at the same time using allen wrench at each end 18 Use a ruler to position round belt pulleys back into place 19 Reinstall flat green belt removed in step 1 20 Spin the shaft to check 21 Repeat steps 1 20 for bottom shaft 22 f infeed end was the only area that was a problem replace all covers and turn on power If the dump end is a problem continue with the following procedure 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ADJUSTMENTS amp REPAIR INFORMATION
24. RED WUT nEn BLK WHT RED WHT RED 24 RI 104 sau 1 RED BLU 2 BLK 10 CLUTCH BRAKE OUTPUT BLK CLR YEL E LK GRN a BRN c sd rer I j I lt l U d al amp g amp P MATL H GBR SYSTEMS CORPORATION FNSH H 12 INSPIRATION LANE CHESTER CT 064 TEL 860 9561 NEXT ASSY USED IN ORIGINAL APPLICATION DRAWN E HARRIS j LEC Si 2 Dl 30 LA EDGES amp CURNERS Cree THIRD ANGLE PROJECTION BENE SIZE DwG ND E EP N ju s D OR THE INFORMATION ITTED TO ANY L WITHOUT UTHORIZED CONSENT SCALE 4 1 SHEET 1 1 SH SIE4 DWG ND H 9 597 31570 316 REVISIONS APPROVED EJH DESCRIPTION RELEASE ECN 93 ZONE REV ORIGINAL INTERLO INSERTER INTERFA
25. The creeper conveyor motor is actuated whenever the paper demand wand has been lowered and trips the switch in the feed hopper There are four connectors that plug into the controller housing speed control enable circuit ac voltage and motor output C 12 FEEDER MOTOR CONTROLLER In the above picture on the left is the feeder motor controller A close up is on the right It is a PWM controller and provides excellent voltage constant over the speed range of the controller 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 17 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 18 C 13 ELECTRONICS SCHEMATICS The following is a list of the requisite schematics for the 438 system Drawing Description Page Drawing Description Page 042 31549 300 Reader Backplane F30 21 V4 3208 BULK LOADER SCH 042 31350 300 DC Distribution PCB 438 V4 Elect 22 V4 CUTTER BULKLOADER MODULES 196 30500 300 Schematic Feeder 23 CABLE 22 23 24 27 196 30501 300 Schematic Creeper Contl Motor 24 V4 INK MARK_KICKER_MOD9_CABLES 17 196 30502 300 Schematic Feeder Motor PCB 25 19 32 196 30503 300 Schematic Controller Creeper Motor PCB 26 V4 LINE CODE READ_CP30 597 31570 301 AC Power Distribution Control Cabinet 27 V4 MODULE8 CABLE22 23 24 27 597 31570 302
26. amp REPAIR INFORMATION 071 XXXXX 400 SECTION E PAGE 18 28 Attach Accumulator back onto Folder Reinstall all covers 14 Slide top shaft into place and reinstall green belts rollers 29 Turn on power and pulleys using bottom shaft as a guide Reinstall screws for bearing housings 15 Replace new key 186 031135001 on left side and reinstall spacer timing pulley with timing belt Pulley must line up with key 16 Apply blue Loctite 188 24205 to top shaft end screws and tighten simultaneously 17 Remove screws from bottom shaft 18 Remove spur gear and spacer from bottom shaft on right side See photo at step 7 19 Remove spring by removing screw See photo above 20 Remove left side plate with bearing housing by removing large screw and washer in right side Be careful not to lose pivot point sleeve 21 Remove right side plate with bearing housing by removing large pivot point screw Be careful not to lose pivot point sleeve Pivot Point Sleeve 22 Replace both ball bearings with new ball bearing 186 031112035 in both bearing housings 23 With both plates and bearing removed Slide new bottom dump shaft 186 032017834 on by pushing end of old shaft off and moving pulleys and rollers into place 24 Reinstall plate and bearing housings with pivot point screw and spring screw Tighten hex nut back against chassis 25 Replace spur gear and spacer 26 Apply blue Loctite 188 24205 to bottom shaft end screws and ti
27. amp SERVICE MANUAL ISSUE 2008 05 INTRODUCTION 071 28558 401 SECTION A PAGE 38 A 9e Line Read Setup 3 Usage It is interpreted as a binary number This number must be constant for all the pages within a package This number should sequentially Setup Line Read Setup 3 The reader must be told at what point in a code field it will see page group parity and inserts Depending on the code format this indicates when the field begins how many lines it consists of and the maximum value of the field Page Seq Mark Stat 6 Length 3 Min 1 Max 7 IncType 0 This is crucial to proper reading and the operator should have a master I l code template that shows the location and value of each line in a code field If certain fields are omitted enter an arbitrary number related to the Inserts Mark Stat 11 Length 6 specific code in that field 1 l 1 Example Where the code is page field first and there are three lines for the GBR Systems Line Read Setup 3 Group Seq Mark Stat 3 Length 3 Min 1 Max 4 I l t l t 1 t 1 Item Verify Stat O Length 0 Min 1 Max 0 page field the correct set up would be Begin 01 Length 03 Max value 7 i i Group Seq Mark Gate At ee ge I PE EP k M k 10 2 T 4 Purpose Identify each page as being a part of an individual package The 14 PNGUDUE c RAN sequential incrementing of the number ensures the document s printed LES z
28. 04 Built Feb 8 2006 11 26 12 D 4a Speed Test Pressing the green Power On switch on the keyboard will start the feeder and folder motors and display the speeds of the feeder folder transfer conveyor and read encoders 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 D 4b Test Cycle Press Test Cycle for 100 msec On 300 msec Off cycle Press Test Cycle again to stop test The speeds indicated are approximate inches per second NOTE The FEED and READ speeds must be within 5 of each other to ensure normal operational condition PROBLEM ANALYSIS SECTION D PAGE 5 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 D 5 IO 96 BOARD INPUTS AND OUTPUTS D 5a Orientation Use this screen to test inputs and outputs e Press TEST and then 10 144 Board to enter screen e Toggle the pointer to the desired input or output using the Side and Top information from the next section e The name of the output or input will be displayed when the cursor is positioned on its Side and Top Location block e Inputs will change state when sensors are blocked or encoders are rotated e Use the Toggle button to toggle the outputs on and off Interlocks must be closed Input Output Test 10144 Base Addr 240 IRQ 5 108255 Base Addr 1e8 IRQ 0 Mode 91 00000000 00111111 11112222 a 00000000 00111111 11112222 01234567 89012345 67890123 fex 01234567 89012345 67890123 0 30010010 0
29. 1 16 Output Inserter Master Relay 1 17 Output Station 1 Error indicator 1 18 Output Ext Feeder Cutter Dmne Out 1 19 Output Postal Divert 1 20 Input Ext Feeder Cutter Demand In 1 21 Input Inserter Run Signal 1 22 Input Cutter Sensor 1 23 Input Station 1 Sensor PROBLEM ANALYSIS SECTION D PAGE8 Side Port Top Point Type Input Output Description 2 00 IFA2 RA Conv Input Sensor 2 01 Not Used 2 02 Not Used 2 03 Not Used 2 04 Not Used 2 05 Not Used 2 06 Not Used 2 07 Not Used 2 08 RR IF42 RA Conv Motor Enable 2 09 Not Used 2 10 Not Used 2 11 Not Used 2 12 Not Used 2 13 Output Feeder Brake 2 14 Output First Page Hold Brake 2 15 Output First Page Hold Clutch 2 16 Input Ink Mrk RA Conv Pres Sensor 2 17 Output RR Creeper Motor Enable 2 18 Not Used 2 19 Not Used 2 20 Not Used 2 21 Not Used 2 22 Not Used 2 23 Not Used 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 PROBLEM ANALYSIS SECTION D PAGE 9 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 PROBLEM ANALYSIS 071 28558 401 SECTION D PAGE 10 D 6 ERROR CODES ERROR A unique error number The first two digits specify a machine area or module The last three define the specific error EVENT The event or process being monitored EVENT CHECK The mechanism or thing used to monitor the event ERROR ON The rea
30. AC Power Distribution Chassis 438 V4 Elect 28 597 31570 303 DC Power Distribution Control Cabinet V4 29 Elect 597 31570 304 DC Power Distribution Chassis V4 Elect 30 597 31570 305 E Stop amp Interlock Sheet 1 of 2 31 597 31570 305 E Stop amp Interlock Sheet 2 of 2 32 597 31570 306 O Interconnect 438 V4 Elect 33 597 31570 307 O Interconnect Rack Port 0 34 597 31570 308 O Interconnect Rack Port 1 35 597 31570 309 O Interconnect Rack Port 2 36 597 31570 310 O Feeder Module 1 37 597 31570 311 Exit Conveyor Module 4 438 V4 Elect 38 597 31570 312 Keyboard Module 5 438 V4 Elect 39 597 31570 313 Folder Accumulator AC Power Distribution 40 438 V4 Elect 597 31570 314 Folder Accumulator Control 438 V4 Elect 41 597 31570 315 Flats Collector Control 438 V4 Elect 42 597 31570 316 Inserter module 7 438 V4 Elect 43 597 31570 317 SAT 520 CPU Chassis 438 V4 Elect 44 597 31570 318 SAT 520 CPU With Touch and Read System 45 438 V4 Elect 597 31570 319 Line Code Read F30 438 V4 Elect 46 SUE NO 2 j SH SST toVDC 5VDC PVC 12VDC le y pE 1ev DC 12V pc EVE 1 vC REVISIONS 4l NE REV DESCRIPTION DATE APPROVED ORIGINAL RELEASE ECN 9t 394 08 15 06 EJH
31. Calculation Done when pack is transferred to the Inserter Package Weight Envelope Weight No Pages Page Weight Insert1 Inserti Weight Insert2 Insert2 Weight through 8 inserts If Package Weight is greater than or equal gt to Meter 1 to 2 Weight Break Value e Then Meter 1 operates If Package Weight less than lt Meter 1 to 2 Weight Break Value and greater than or equal gt to Meter 2 to 3 Weight Break Value e Then Meter 2 operates If Package Weight less than Meter 2 to 3 Weight Break Value and less than Meter 1 to 2 Weight Break Value e Then Meter 3 operates 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 INTRODUCTION SECTION A PAGE 53 A 13a Three Meter Example Meter 1 to 2 Weight Break Value 30 Meter 2 to 3 Weight Break Value 20 Package Weight Meter 1 Meter 2 Meter 3 Q X X X X X x Three Meter Setup Lineread Setup e Select Postal Meter Divert Enable OFF to operate from Weights ONLY Inserter Setup e Postal Meter By Weight Check ON to enable Postal Meters Inserter Setup 2 e Postal Meter Divert Postal Meter 1 e Meter ON AT in degrees e Meter OFF AT in degrees e Meter Position STA 6 stations after envelope insert station e Enter Point Option PT 9 Postal Meter Divert Inserter Setup 3 e Postal Meter 2 e Meter ON AT in degrees e Meter OFF degrees e Meter Position STA 6 stati
32. Check at Feeder Power On CHECK VALUE ADJUST VALUE ANALYSIS Feed Sensor ON 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 REPAIR INFORMATION SECTION D PAGE 13 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 D 6c 13xxx Accumulator Error Description 13000 Stack Error Purpose EVENT Page passing through Acc Stack Sensor EVENT CHECK StackTimer CHECK VALUE 500 msec ADJUST VALUE ANALYSIS Time exceeded 13001 Misfeed Error Purpose EVENT Acc Clutch ON page passing out of Acc Presence Sensor EVENT CHECK NoDumpTimer CHECK VALUE 150 msec Sheet Length 150 Speed ADJUST VALUE ANALYSIS Time exceeded D 6d 14xxx Folder Error Description 14001 Jam In Folder Purpose EVENT Accum Clutch ON to lead edge Folder Exit Sensor EVENT CHECK FolderExitTimer CHECK VALUE 400 msec ADJUST VALUE Engineering Value 4 ANALYSIS Time exceeded 14002 Jam At Folder Exit Purpose EVENT Accum Clutch ON increment Lead edge at Folder Exit Sensor decrement EVENT CHECK PackageCounter ERROR ON 2 CHECK VALUE 2 ADJUST VALUE Engineering Value 4 14820 SPEED LOW Purpose EVENT Folder Encoder Sensor EVENT CHECK Calculate and Average speed CHECK VALUE 25 inches per second ADJUST VALUE REPAIR INFORMATION SECTION D PAGE 14 D 6e Error 15001 15002 15003 15002 15003 ANALYSIS Speed less than value 1
33. Comms list messages 1 F Extra ExitComm list messages times in msec Demand 28 L p Values Enable Password Range 0 gt 1 Inc time receive character for Sure Feed Bit level assignment D7 D6 D5 D4 D3 D2 D1 DO D7 gt D1 MAR 0 bs aedes or unassigned D0 ExitComm messages isables password to access Engineering Values 20 0 Exit Demand Switch Range 0 gt 1 Inc 1 29 3 ic Exit Demand power On Cycles Range 0 gt 99 Applies to Hopper Fill and Conveyor 0 No Exit Demand required 1 Exit Demand required for Default of inserter demand cycles before Conveyor for Sure Feed 38 outputs a package 21 215 Exit Demand Time Out Range 0 999 Inc 1 30 2 ee Cycle Machine Power Default 60 60 seconds to shut down on no demand Range 1 gt 2 Range 0 to 999 seconds 1 Commport on U Default Commport on Serial Expansion PCB 22 3000 Jam At Out Time Range 0 gt 9000 Inc 10 Default 3000 3000 msec to pass pack through exit 31 700 brun ON OFF Time Cycles Range 500 gt 700 sensor Range 0 to 9000 msec nc 5 700 Default Debounce time in msec to acknowledge 23 350 Xcvy Jam At In Time Range 0 gt 9000 Inc 10 cycling of POWER ON Button Presses from OFF to ON Default 500 500 msec to pass from folder to in sensor ON to OFF Pange 9 109008 MERG 32 100 Straight Conveyor Table ON Time Range 5 gt 500
34. Corrections of the fold length are made by turning the fine adjustment knob 1 A change in the folding speed also changes the fold length Therefore the set up speed must be maintained NS Du ee Skewed Folds tib out of square folds occur when the paper is fed at the right angles with respect to the fold rollers This can be corrected as follows eM L e Mark the leading edge of a sheet and feed it through the fold unit 2 e Tomake the deviation more obvious exaggerate the skewed fold by hand 3 e Open the folded sheet and place it in front of the roller infeed section 4 e Adjust lower dump rollers on exit end of accumulator through hole indicated OWER DUMP ROLLER oOo NT Ue B Cx H t HB Out Of Square Paper If the paper is not cut exactly at right angles the folded sheet may show points By turning a setting screw the fold plate stop can be made parallel to the out of square paper Note Make this correction only Correction on Comb
35. EOG At is used as an added security aid If Not EOG is checked the code block must not have a mark in this location except at the end of the group Ink Mark At sets the position in the code block to assign an ink mark when required PM Divert At Postage Meter Divert is a signal provided by the computer when the postage weight of a package exceeds the limit of the postage meters on the inserter The signal is delivered at the Postal Meter Divert Mark Subset At Seq Stop At Unseal At Parity Mark not available at this time Purpose Adds parity error checking to the code Usage This location is used to maintain an even number of solid marks within a code Note The fields that are marked Optional can be eliminated by operator configuration of the machine However when a data field is eliminated package security and integrity suffers Subset Mark Press OK 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 INTRODUCTION SECTION A PAGE 40 A 9f Line Read Setup 4 7 Press BLACK a second time when the voltage reaches 0 the Setup gt Line Read gt Setup 4 black bar is directly under the light 8 Remove the paper from under the light and press TRIP GER Systeme Line Rew Setup 4 a Eventlist will say finished when done Gain Set At Lamp Set At 200 Offset 1 At 109 e TRIP POINT 1 value should be between 40 and 150 1 I e OFFSET 1 should be between 100 and 250 w If the
36. Exit Demand and Exit Sensor on exit conveyor Inserter Station 1 Sense CHECK VALUE ADJUST VALUE ANALYSIS Inserter Station 1 Sensor covered for 6 demands Sensor blocked 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 REPAIR INFORMATION 071 28558 401 SECTION D PAGE 11 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 REPAIR INFORMATION 071 28558 401 SECTION D PAGE 12 D 6b 12xxx Feeder Error Description 12001 No Feed Error Purpose make sure a page is fed when the clutch is energized EVENT Feed Clutch ON page lead edge to Feed Sensor EVENT CHECK NoFeedTimer CHECK VALUE 500 msec ADJUST VALUE Cause page did not feed within the 1 2 second time window after the clutch was engaged 12820 DOUBLE PAGE FED Purpose to stop the feeder when two pages are fed simultaneously EVENT Under Feed Sensor Double Detect Sensor EVENT CHECK DoubleDetectCount CHECK VALUE 2 ADJUST VALUE Cause During a single feed cycle the computer will check the Double Detect Sensor several times If the sensor reports two pages during more than one of the computer checks the computer will shut down the feeder and post this error 12821 MISSED PAGE Purpose to let the operator know when overlapping pages may have been fed EVENT Page lead edge to Feed Sensor next page lead edge to Feed Sensor EVENT CHECK Page lead edge to Feed Sensor CHECK VALUE ADJUST VALUE ANALYSIS e No page trail edge Trail ed
37. Folder Tach 0 04 Input Demand Signal 0 05 Input Inserter Deg Encoder 0 06 Input Not Used 0 07 Input Not Used 0 08 Input Start Stop Switch 0 09 Input Cycle Switch 0 10 Input Dump Switch 0 11 Input Interlock Sense 0 12 Input Exit Conveyor Pkg Presence Sensr 0 13 Input Exit Conveyor Dischrg Sensor 0 14 Input Enc Home Signal 0 15 Input Not Used 0 16 Input Double Detect Sensor 0 17 Input Folder Exit Sensor 0 18 Input Accum Presence Sensor 0 19 Input Cutter Ready 0 20 Output Dump Clutch 0 21 Output Exit Conveyor Clutch 0 22 Output Exit Conveyor Brake 0 23 Output Accumulator Brake 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 PROBLEM ANALYSIS SECTION D PAGE 7 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 Side Port Top Point Type Input Output Description 1 00 Output Feeder Clutch 1 01 Output Folder Motor Enable 1 02 Output RR Feed Motor Enable 1 03 Output Not Used 1 04 Output Inserter Sol 7 1 05 Output Inserter Sol 1 1 06 Output Inserter Sol 8 1 07 Output Shingle Conv Motor Enable 1 08 Output Inserter Sol 2 1 09 Output Inserter Sol 3 1 10 Output Inserter Sol 4 1 11 Output Inserter Sol 5 1 12 Output Inserter Sol 6 1 13 Output Env Pull or Shuttle 1 14 Output Ink Mark Kicker 1 15 Output Envelope Flap
38. Line Read Setup 0 GBR Systems Line Read Setup 0 B amp H GBR Setup 4 GBRCode8 GBRCode16 Job Number zode u Job 5 Line Read Code 5 Reset 1 Line Get B amp H ProbeA EdgeA ProbeB EdgeB Calib Version Sensors 0 0 0 0 Monitor Events 10 06 56 Powered Up 10 06 57 LineReader STDBUS Interface Only 10 06 57 LineReader GBRCodeSTB Interrupt Disable 10 06 57 LineReader GBRCodeACK Interrupt Disable 10 07 01 Lineread Setup Started 10 07 01 Lineread Setup Done 10 07 02 LineReader Software Version 08103 003 12 54 16 E 1 G 1 P 0 T 0 Z 0 D 0 1 000000000000 L 1100010001000000000 Ready Note Refer to Section A 9 for an explanation of GBR Line Code Read Setup 1 Refer to Section A 7j Setup 2 Refer to Section A 7k Setup 3 Refer to Section A 71 Setup 4 Refer to Section A 7m Select Line Read Type B amp H Read GBR Read GBR Code 8 GBR Code 16 Job Number System will save all the parameters for up to 10 line code jobs To program Screens Pressing the OK button in each setup screen saves those parameters to the job number selected Reset Job Press this button to reset the job parameters to the default values for the job selected Line Calibration Note Used only for B H Line Read or GBR Line Read Do not try to use this feature for GBRCode8 or GBRCodet6 it will not work This function will calibrate the line code reader for proper location of marks for interpretation of code Before
39. SYSTEMS CORPORATION 10 INSPIRATION LANE CHESTER CT 06412 226 9561 438B NEXT ASSY USED ON ORIGINAL APPLICATION SLE DRAWN E HARRIS ERCUNNECT RAC INTERPRET DRAWING PER ANSI Y14 5 SIZE DWO ND TY OF GBR SYSTEMS LE UPON REQ DR THE T WRITTEN nae SCALE SHEET alae 11 1 l p SIZE B DWG NO Q7 SH REVISIONS 31 f ZONE REV DESCRIPTION APPROVED ER S page ORIGINAL RELEASE ECN EJH pe OB INTERC Baus c MES B JU ha n 8 20 EXT FEEDER lt min CUTTR_DEMAND IN 6 lt 21 INSERTER r RUN SIGNAL SENSOR el
40. There are five 5 safety interlock switches that will interrupt power to the conveyors and folder whenever a cover is opened D 1 Feeder Cover Interlock 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 3 Folder Upper Cover Interlock INTRODUCTION SECTION A PAGE 10 5 Transfer Conveyor Cover Interlock 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 INTRODUCTION 071 28558 401 SECTION A PAGE 11 A 4 MACHINE SPECIFICATIONS Listed below are specifications for the 438 Throughput Speed Max 30 000 documents per hour Material Paper Weights 20 75 GSM to 24 90 GSM Inquire for heavier weights Paper Size 7 x 7 178 mm x 178 mm to 11 x 14 305 mm x 356 mm Loading Capacity 1 500 sheets of 20 bond Fold Types C Z V amp DOUBLE V Porosity 20 Gurley seconds Stiffness 20 Lb Stock 170 225 Gurley Stiffness Units 24 Lb Stock 250 300 Gurley Stiffness Units Cross Grain Stiffness 20 Lb Stock 8 125 Gurley Stiffness Units 24 Lb Stock 12 150 Stiffness Units Moisture Content 4 6 by Weight Components Feeder Bottom feed top loading for continuous operation Optical Reader Optical code reading for group batch recognition sequencing and double printing control of 1 to 12 document groups Larger group batch setting available upon request Folder 4 plates Group selector Manual group selecti
41. amp REPAIR INFORMATION 071 XXXXX 400 SECTION E PAGE 11 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 XXXXX 400 E 2e Infeed Drive Shaft and Bearing Replacement 1 Remove flat green belt by carefully prying up spring tension idler 2 Remove the screws on each end of the top shaft by using an allen wrench in each end and turning in opposite directions Infeed Drive Shafts 186 032017499 ADJUSTMENTS amp REPAIR INFORMATION SECTION E PAGE 12 Screws to be removed for removal of shaft 3 Start removing parts screw washer long spacer flat pulley and key 4 Loosen screw for bearing from inside Slide bearing housing off Push bearing out 77 left side 6 Slide shaft over removing pulleys one at a time until complete shaft is out 7 Loosen screw without marring shaft by holding at timing 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ADJUSTMENTS amp REPAIR INFORMATION 071 XXXXX 400 SECTION E PAGE 13 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ADJUSTMENTS amp REPAIR INFORMATION 071 XXXXX 400 SECTION E PAGE 14 8 Remove parts screw washer 2 spacers pulley key small 12 Slide shaft back into place with each round green belt and spacer bearing housing with clip pulley back into position Use bottom shaft as a guide Note The turned down end is shorter on left side 2 34 13 Replace screws for bearing housing on left side that were than on right
42. ananassa eiui aqapana 45 10 A 10f Bar Read Setup 2 cree etr er tenes test Sipas 47 A 10g Adjusting the Paper Guide Belts seen 47 A 10h Bar Read Setup 3 ana tre terere ap a mes sa ayu aves 48 A 10i Bar Read Setup as asun a RERO UTER TS 49 A 12 READ ZONE DIAGRAM amp S 50 A 13 POSTAL METERING eeeeeeeee 51 A 13a Thr e Meter Example u naa tee rr nro t 54 16 A 13b Two Meter Example oper nre pee ass 54 18 14 SOFTWARE UPDATES VIA EMAIL 55 ISSUE 2008 05 INTRODUCTION SECTION A PAGE 1 A 1 RELATED MANUALS The following manuals are available for the 438 e 071 28855 402 438A amp 438B PARTS MANUAL A 2 INTRODUCTION TO THE MANUAL This manual is intended for service technicians and is organized to enhance preventive maintenance troubleshooting and repair of the 438 Installation of the 488 is also described Note The exact screens and functionality are software version dependent Specific features may be available or not or have default settings according to the software version A 3 INTRODUCTION TO THE MACHINE A 3a Feeder Section The 438 s feeder is bottom fed top loading for continuous operation with a capacity of 1500 sheets 20 Ib bond or offset paper Creeper Conveyor The Creeper Conveyor is comprised of two bla
43. group number and the page that was just fed did not If the group did not change within the set check to see that the proper barcode is printed on the page and that the barcode matches the specifications Check to see that the proper barcode job is selected The previous group had the same group as the current The maximum number of sheets set in the system has been reached Change setting if a larger pack size is desired REPAIR INFORMATION SECTION D PAGE 23 ISSUE 2008 05 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 REPAIR INFORMATION 071 28558 401 SECTION D PAGE 24 The package size has exceeded the machines capabilities nn039 nn040 nn041 nn042 nn043 nn044 nn045 nn046 UNEXPECTED EOG NO RESPONSE TIMEOUT BAD READ bar read MAX PAGE NOT NO PAGES bar read INVALID GROUP NUMBER bar read BAD CHECK DIGIT bar read EXPECTED END OF SET bar read EXPECTED PAGE ZERO bar read 438 OPERATOR amp SERVICE MANUAL 071 28558 401 The end of group mark was read but not expected The document sequence is out of order Misread Bar code misprinted The reader did not return a reading in the proper amount of time Make sure that the barcode reader is lined up with the code Make sure that the barcode print on the paper is good quality The bar code reader returned an error Make sure that the barcode reader is lined up with the code Make sure that the bar
44. held by the flat green belts Positioning the trailing edge of the document at the centerline of the lower forward most shaft provides the desired document position When the gripper arm removes a package from the transfer conveyor the flat green belts of the Transfer conveyor will creep if more than 3 4 of inch of the package is being pinched by the flat green belts The creeping of the flat green belts will cause the packages to become improperly gapped in the transfer conveyor RAILING EDGE OF DOCUMENI Transfer Conveyor Figure 438 OPERATOR amp SERVICE MANUAL 071 XXXXX 400 ISSUE 2007 09 E 4f Transfer Conveyor s Outfeed Guides Position It is recommended that the transfer conveyor arm be positioned parallel to the deck of the inserter and it should be close enough to the deck so the outfeed guides do not need to drastically deflect the folded document This will help prevent the flat green belts from creeping and ease the extraction force required to remove the folded document SMART FEEDER INSERTING MACHINE eee GOOD POSITION POOR POSITION PACK TOO LOW POOR POSITION PACK ADJUSTMENTS amp REPAIR INFORMATION SECTION E PAGE 31 438 OPERATOR amp SERVICE MANUAL ISSUE 2007 09 071 XXXXX 400 E 4g Fold Quality Consistent fold size is required to prevent the package size p
45. input and output modules are restrained under a bar that is fastened with screws to the boards on both ends and in the middle The input modules are white and the output modules are red The white input modules come in two flavors a regular and a high speed The red output modules also come in two flavors regular and reed relay The high speed white modules are used for input pulses that are very short The red reed relay output modules are used in circuits where the current draw is high e g motors It is easy to tell if the module is working by looking at the appropriate LED device next to the module If it is on it the module is said to be active ELECTRONICS SECTION C PAGE 11 438 OPERATOR amp SERVICE MANUAL 071 28558 401 C 8 SINGLE CHANNEL READ CARD DALLAS DS1286 WATCHDOG 002443 094530 GBR Part Number w GBR Line Code 042 26908 500 This card is provided only when certain options are included in the 438 Function e Interfaces with the Pc104 serially e Processes signals from the GBR TJ or B H Line Code Cards e Processes Read encoder signals e For B H Line Read process edge detect and bar detect LED Indications The following LED indications apply only when using B H line code ISSUE 2008 05 ELECTRONICS SECTION C PAGE 12 LED 1 ON OFF every second indicating operation except when LED 2 is lit LED2 indicates busy line code read taking place calibration read taking place or m
46. is buckled The sheet is now pinched by fold rollers 2 and 3 The rollers 2 and 3 pull the folded sheet out of the 1 fold plate while driving it to the next fold plate After the last fold the sheet is transferred by the delivery rollers to the delivery belt on a delivery table or into the hopper or open station of an inserter by means of a transfer conveyor Note The fold rollers are made of polyurethane and steel sectioned material Clean using alcohol and a soft cloth Fold Roller Diagram Figure ADJUSTMENTS amp REPAIR INFORMATION SECTION E PAGE 19 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ADJUSTMENTS amp REPAIR INFORMATION 071 XXXXX 400 SECTION E PAGE 20 E 3d Fold Plate Positions E 3c Components of the Fold Unit In the fold unit 38 4 there are four positions for the fold plates Components and operating elements of the fold units 1 Noise covers Fold Roller Diagram Figure 2 Paper thickness measuring device 3 Fold roller gap setting adjustment knobs 4 n a 5 Handwheel 6 Folder power switch E 3e Position the Fold Plates and Deflectors E 3f Setting the Fold Length on a MM 438 Adjustment by means of the fine adjustment screw is only possible when the lock screw for the fold plate stop has been tightened Light paper grades move the lip forward by turning the screw counter clockwise Heavy paper grades move the lip backward by turning the screw clockwise 438 OPERATOR am
47. running a special Calibration sheet through the machine The Calibration document has two precisely placed marks on the document These marks provide the needed reference points to calibrate the machine The same sheet is used for all three settings Description of A Calibration Document 438 V4 OPERATOR amp SERVICE MANUAL 071 28558 401 A Calibration document has two precisely placed Line Code marks on a document The first Line Code mark is placed one inch from the leading edge of the document The second Line Code mark needs to be precisely placed 6 inches away from the first Line Code mark No other marks can be in the area between the two marks This will give the Line Code Recognition system the expected reference distance to calibrate to the machine The Line Code Recognition card uses the two marks on the Calibration document to count the number of encoder signals that occur between the marks If the number of encoder signals counted are within 15 96 of the expected number of encoder signals it is considered a valid calibration value ISSUE 2008 05 Calibration Procedure FOR 1 10 1 8 AND 1 6 SPACED LINE CODES 1 Check all mechanical setups in the machine Examples e Friction feeder is free of mechanical binding e Singulator is adjusted properly e Documents are processed through machine without distorting the paper e All paper hold downs are set up properly e Paper rails are set to the proper width 2 Line Read Setup 4 an
48. the document has cleared the stacking ramps Sensor Modules The Sensor Module for the Accumulator and Stack Sensors are accessible by removing the right side accumulator cover 7 Sensor Reflector Part of Sensor 6 Belt Conveyor 186 031033097 5 Brake 121 26564 000 4 Stacking Ramps 186 032051604 3 Stacking Rollers 177 28468 600 2 Accumulator Presence Sensor 057 32041 000 1 Accumulator Stack Sensor 057 32041 000 Item Description Part Part List INTRODUCTION SECTION A PAGE 7 A 3c Folder Section The folder is capable of placing 1 to 7 sheets in a C Z or double V configuration It is fed by the Accumulator Section Buckle Plates Manual adjustable plates which set the distance of the fold from the edge of the paper Rollers Used to nip the paper as it is buckling creating the fold Folder Drive Motor A motor which drives all folder shafts and rollers and the upper and lower dump shafts on the accumulator Folder Speed Encoder An encoder located on the exit roller shaft which provides a folder speed signal 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 INTRODUCTION 071 28558 401 SECTION A PAGE 8 Folder Section Representation A 3d Exit Conveyor This monitors the presence of paper packages in the first station of the transfer Straight Conveyor AM52 Delivery conveyor This is an optional stand alone straight conveyor that enables the 438 to be
49. to be either a 0 or 1 depending on what minimum page number was selected in the page setup If the page was page 1 check to see that the proper barcode is printed on the page and that the barcode matches the specifications Check to see that the proper barcode job is selected Group code was not in specified range i e 0 7 Similar to Group Out of Range error page range must be within 1 7 Invalid command Cycle machine power The program has run out of non volatile ram You should never get this error If you do get this error either the software is bad or the CPU board is bad Some of the preset parameters have fallen out of their defined maximum or minimum range If new EPROMS were just installed this error might occur If this is the case ignore the error If the battery jumper was pulled from the CPU board this error might occur If this is the case install the battery jumper and ignore the error If neither of the previous scenarios happened the CPU board is probably bad Data in the non volatile ram was changed Power to the CPU was unplugged directly at the board Noise in the 120 VAC power Hardware failure on reader board Battery failed or battery jumper missing Bad CPU 186 board Hardware failure on reader board Battery failed or battery jumper missing Bad CPU 186 board Hardware failure on reader board Battery failed or battery jumper missing PC 104 CPU Board 438 OPERATOR amp SERVICE MA
50. total is an even number then an PARITY ERROR E18019 is generated and the machine stops The Parity Mark is present to always make the total odd Even Parity Counts the total number of marks read If the total is an even number then the parity test is passed If the total is an odd number then an PARITY ERROR E18019 is generated and the machine stops The Parity Mark is present to always make the total even None Default Sequence Shutdown Explain e Clr Last Clear Last e Stop Last Stop Last e Clr 1 Clear First e Stop 1 Stop First e None Item Verify Explain e First Pg e Last Pg Off Ink Mark e Divert e Error No index entries found Random Mark INTRODUCTION SECTION A PAGE 34 NO STOP MAX ERRORS Setting No Stop Max Errors to 0 allows the machine to function normally and stop on a read error Setting to 1 enables the No Stop function which when a read error is encountered on a pack being accumulated that pack the previous pack that had been accumulated and the folded pack sitting in the first station of the transfer conveyor will all be set as bad packs These packs are diverted at the end of the inserter This use of Divert has priority over Divert by Mark and Divert by Weight To use this function Bad Pack Stop Enable in Inserter Setup 1 must be deselected Priority Levels for Pm Divert are 1 No Stop if selected in Line Read and Line Read is selec
51. 0 6 JH NAAAMAAAIAAAV V V NV NUNA NONE AR OR P MA A I 8765 1 15 KEYBOARD sss zs PRINTER Wh ERA y s sr ORT HS B 0 48 ORT n N M y a J J11 N V N N V 14 2 15 9 sites 1 1 A VV VN NN VV WWW Y MATL FNSH ARE INCHE TOLERANCE UNLESS OTHERWISE SPECIFIED DMENSIO AR NCHES S 438B al i NEXT ASSY USED UN GBR TEL SYSTEMS CORPORATION 12 INSPIRATION LANE CHESTER CT 860 526 9561 06412 ORIGINAL APPLICATION DRAWN E HARRIS CHECKED INTERPRET DRAWING PER ANSI Y14 5 CHASSIS 438 ELEC NL
52. 0 Station O Station 0 occurring Range 0 to 990 j j l Station The location on the deck of the inserter the Kicker will operate from when selected Range 0 to 25 0 disables the kicker routine Station is referenced from the envelope insertion station in Inserter and from the first station in Postar outside of the transfer conveyor Station must be set to Kicker On Time 250 Delay 100 Station O ShiftAt 150 greater than 0 t t 1 t Shift At Logic shift for data adjustable to enable data to be shifted relative to inserter Home position thereby ensuring the Kick comes at precisely the Ready correct moment Envelope Station Vacuum is normally enabled At 230 This is the position of the encoder in degrees at which vacuum is applied to the envelope hopper Station is normally set at 2 Envelope Flap Detect is normally set On at 10 Off at 350 and Insert Station 1 this is the location of the flap detect Ink Mark is an optional device that places an ink mark in varying locations to sort zip codes visually OFF At is the number of chain movements AFTER envelope insertion Ink Marking is normally located at Station 7 PM Divert is normally set On At 10 Off At 12 and is normally located downstream from station O Ins Sta Vac OnAt 100 Logic Shift 90 Bad Pk Stop OnAt 1 l I i l 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 INTRODUCTION 071 285
53. 0011100 10000011 80010010 00011100 10000011 1 00000000 00000000 00001000 2 00000000 00000101 00000000 3 00000000 00000000 00001111 NC 4 00000000 00000000 00000100 VO POINTS 5 00000000 00000000 00000000 woPORTS Feed Sensor PROBLEM ANALYSIS SECTION D PAGE 6 D 5b Locating I O LED s and Card Components Use the IO 96 reference chart in the next section for the screen and card LED locations Use the information in the LED column to locate the correct rack card and LED on the card For further troubleshooting reference the card configuration number located on the front of each card and on the card itself Use this configuration number to locate a representation of the specific card in the parts section Each of these parts drawings includes a number for the schematic that supports that card Note Some of what you see on the screen is for future use At this time the first three rows on the left hand half of the screen are used for I O testing The bottom three rows are set aside for the future The same holds true for the right half of the screen None of this half is currently being used D 5c Reference Charts Side Port Top Point Type Input Output Description 0 00 Input Feed Sensor 0 01 Input Accumulator Stack Sensor 0 02 Input Feeder Tach 0 03 Input
54. 071 XXXXX 400 SECTION E PAGE 15 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 XXXXX 400 E 2f Dump Shaft and Bearing Replacement 1 Remove right cover on folder to expose inside folder Place hardware in safe place 2 Remove round green belt 3 To create space for Accumulator to be pulled off unplug green phoenix block and clip ty wraps or if there is a loop of extra cable only unclip along top Loosen nut on both sides Support Accumulator while removing Set on bench near Folder ADJUSTMENTS amp REPAIR INFORMATION SECTION E PAGE 16 Loosen both screws on top dump shaft Remove top guide Loosen setscrew in spur gear and remove Loosen setscrews on round belt pulleys and rollers LIO s 8 Remove timing belt and pulley from top shaft Note location of recessed side of pulley Remove key and spacer 9 Remove screws for both bearing housings from inside 10 Slide shaft out 11 Remove spacer 312 clip ball bearing and washer 12 Reassemble bearing housing with new ball bearing 186 031112035 13 On new top shaft 186 032017833 slide bearing housing new key 186 031135001 and spur gear Tighten setscrew on spur gear from step 7 Screws to be tighten with loctite in steps 17 and 27 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 XXXXX 400 MATION SECTION E PAGE 17 Larae Pivot Point 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ADJUSTMENTS
55. 08 by GBR Systems Corporation All rights reserved GBR Systems Corporation Copyright protection claimed includes all forms or manner of copyrighted materials and information now allowed by statutory or judicial law or hereinafter granted including without limitation material generated from the software programs which are displayed on the screen such as styles templates icons screen displays looks etc Printed in the United States of America USING THE MANUAL 1 TABLE OF CONTENTS Each capitalized alphabetic character represents a major division within the manual Section A Under each major division the capital letter is followed by a number This represents a subdivision of the major section Section A1 is a subdivision of A n der each subdivision an alphanumeric combination is followed by a decimal and a lower case letter This represents a smaller division under a subdivision Section A 1a is a subdivision of A 1 Section A 1a1 is a subsection of A 1a Each major section of the manual begins with page 1 and is numbered in sequence through that section only Section A begins with page 1 section B begins with page 1 etc This manual is divided into Section A through A detailed table of contents is located on the first page of each section SECTION A INTRODUCTION Machine Orientation Machine Specifications Run and Setup Screens Engineering Values Line Code Read with Setup Screens Laser Bar Code Read w Setup Scr
56. 125 with 1 8 line spacing 0 166 with 1 6 line spacing The minimum distance of the Gate Mark from the leading edge is 0 25 All other marks should be placed with respect to the Gate mark within a 1 4 of a print line of their expected placement REPAIR INFORMATION SECTION D PAGE 27 SECTION E ADJUSTMENTS AND REPAIR INFORMATION E 1 FEEDER 2 E la Description c uqa tau BU e en beaten 2 E 1b Timing Procedures 3 E 1c Feeder Setup and Adjustments 3 E 2 ACCUMULATOR SECTION 9 E 2a Descrption a aces ma S DR NISI ORDRES 9 E 2b Accumulator Clutch and Brake Adjustments 9 E 2c Accumulator Dump Roller Replacement 10 E 2d Accumulator Shaft amp Bearing Replacement 11 E 2e Infeed Drive Shaft and Bearing Replacement 12 E 2f Dump Shaft and Bearing 16 FOLDER 19 E 3a Desctiption arent Rer Eee rentre nete 19 E 3b Fold Principle eder eH PORE 19 E 3c Components of the Fold Unit eee 20 E 3d Fold Plate Positions eee see 20 E 3e Position the Fold Plates and 21 E 3f Setting the Fold Length on a MM 438 21 E 3g Close Fold Plate MM 438 sse 22 E 3h Setting the Fold Length se
57. 58 401 SECTION A PAGE 24 A 71 Inserter Setup 3 GBR Systems Inserter Setup 3 Postal Meter 2 OnAt 240 OffAt 10 Station 7 Point 1 1 1 l t OnAt 280 OffAt 10 Station 7 Postal Meter 3 Point 2 1 1 1 t l l Weight Breaks 1 2 0 2 3 0 1 l t Page Env Wts Page 0 Env 0 t l t l Ins 1 4 Wts 10 20 30 t l t l 1 l 1 l Ins 5 8 Wts 50 6 0 7 0 8 0 Process Status Ready PM Divert Postal Meter 2 and Postal Meter 3 NOTE ON POSTAL METER WEIGHING The 438 can accommodate up to three postal meters PM Divert 2 and 3 are located in Inserter Setup 3 Based on the values entered in Weight Breaks Page Env Wts Ins 1 4 Wts and Ins 5 8 Wts located in Inserter Setup 3 the document will be stamped by the appropriate postal meter The dollar value must be manually entered in the postal meter The value you enter in the Postal Meter Weights can be any unit of measure as long as it is consistent If one weight break is set to reflect ounces all other settings must reflect ounces including the inserts and the postal meter itself Likewise if one is set to reflect grams they must all be set to reflect grams The numbers entered are relevant only to each other 438 V4 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 Postal Meter 1 PM Divert in Inserter Setup 2 is normally set to ON At 200 This will enable the postal meter at the correct time This value may need to be adjusted if the po
58. 5xxx Xfer Conveyor Xfer Cvyr Xcvy Description Jam Error EVENT Pack at Xcvy Sta 1 In Sensor increment Pack at Xcvy Out Sensor decrement EVENT CHECK PackageCounter ERROR ON gt 5 CHECK VALUE 5 ADJUST VALUE Engineering Value 18 Jam At In Sensor Error EVENT INSERTER Xcvy Clutch ON to Pack out of Xcvy Sta 1 In Sensor EVENT CHECK JamAtInTimer CHECK VALUE 500 msec ADJUST VALUE Engineering Value 23 ANALYSIS Time exceeded Jam At Out Sensor Error EVENT INSERTER Xcvy Clutch ON to Pack into Xcvy Out Sensor EVENT CHECK JamAtOutTimer CHECK VALUE 3000 msec ADJUST VALUE Engineering Value 22 ANALYSIS Time exceeded Jam At In Sensor Error EVENT HOPPERFILL Xcvy Clutch ON to Pack into Xcvy Sta 1 In Sensor EVENT CHECK JamAtInTimer CHECK VALUE 500 msec ADJUST VALUE Engineering Value 23 ANALYSIS Time exceeded Jam At Out Sensor Error EVENT HOPPERFILL Pack into Xcvy Sta 1 In Sensor to Pack into Xcvy Out Sensor EVENT CHECK JamAtOutTimer CHECK VALUE 3000 msec ADJUST VALUE Engineering Value 22 ANALYSIS Time exceeded 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 REPAIR INFORMATION SECTION D PAGE 15 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 REPAIR INFORMATION 071 28558 401 SECTION D PAGE 16 15004 15005 15006 15820 15821 22222 EVENT HOPPEHRFILL Paci dnto Xevy Sta In Sensor4o Paclcinte Xevy Out Sensor EVENT CHE
59. A SERVICE MANUAL ISSUE 2008 05 COVER 071 28558 401 A PAGE5 SECTION A INTRODUCTION TO THE 438 V4 SECTION A INTRODUCTION TO THE 438 4 A 1 RELATED MANUALS a sassa aa senses 2 INTRODUCTION TO THE MANUALLI A 3 INTRODUCTION TO THE MACHINE A 3a Feeder S CHon u asnus s ii A 3a Feeder Section e eese eese sessio A 3b X Accumulator Section A 3c Folder Section i eee rpm eher Exit COlVeyOE csi eee Undo nee iei JEXIUCOnDVOY OLD icio eerte epe hee deis A 3e Emergency Stop Interlocks sess A 4 MACHINE SPECIFICATIONS A 5 RUN A 6 KEYBOARD OPERA TION A 7 SYSTEM SETUP SCREEN Aa na saa mu A SP RF Dre er REPERI te QE teris ASTD Feeder Setup irsin soe co ee ener re creta Ac Accumulator o rer aper PRU d Eold eti eios cete cepe ROT onte abr A HR A e Cvyr Transfer Conveyor Setup sss se X Infeed Setup nene AIg Line 5 0 mme Rn i iet A 7h Read Setup 0 asqa wap ettet h aap aaa
60. AL 071 28558 401 ISSUE 2008 05 ELECTRONICS SECTION C PAGE 28 SIZE DwG ND 22 2 Re REVISIUNS ZONE REV DESCRIPTIDN APPROVED ORIGIN AL RELEASE ECN 9394 EJH X i X6 N U as 0 RIEL AAD ELD 8 INTERLOCK OLATED CONTACTS dC TES MATL FNSH H AND ANGLES UNLESS DTHERVISE SPECIFIED 438 DMENSIONS ie REMOVE BURRS SHARP EDC ES amp QR ARE IN INCHES NEXT ASSY TOLERANCE EAL E USED ON GBR SYSTEMS 4 12 INSPIRATION LANE CHESTER TEL 860 526 9561 CORPORATION CT 06412 ORIGINAL APPLICATION DRAWN E HARRIS 2 7 2006 CORNERS THIRD ANGLE PROJECTION INTERPRET DRAWING PER ANSI Y14 5 DC POWER CHASSIS DISTRIBUTION DWG NO 4 SUE SH Y E STOP INTE REVISIONS DESCRIPTION DATE APP XOVED ORIGINAL RELEASE ECN 9 15 06 EJH
61. Bar Read Setup 2 Group Seq Code Stat 2 Length 2 StartBit O LengthBit O IncType 0 1 l 1 l t 1 l Page Seq Code Start 0 Length O StartBit O LengthBit 0 1 1 l l l Inserts Code Start 6 Length 2 StartBit 1 LengthBit 6 l l 1 1 l Demand Feed Code Stat 1 Length 1 StanBa 1 l I l Ink Mark Code Stat 5 Length 14 StarnBit 1 t l j L 1 PmDivert Code Stat 9 Length O StartBit O 1 l 1 1 l Process Status Cancel Ready The software permits a total of 30 characters in Bar Read however physically that isn t always practical due to the length of the code For instance 3 of 9 code is physically larger than 128 code not available on the 438 at this time A code in excess of 15 characters becomes problematic with a 3 of 9 code but a 128 code can easily exceed 20 characters Define the position in the barcode string to extract the information for the following Group Seq Code Start 0 to 30 Start character Length 0 to 5 Number of characters Start_Bit 0 to 30 Starting bit position within character Length Bit 0 to 30 Number of bits IncType Increment Type 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 Page Seq Code Start 0 to 30 Start character Length 0 to 3 Number of characters Start Bit 0 to 30 Starting bit position within character Length Bit 0 to 30 Number of bits Inserts Code Start 0 to 30 Start character Length 0 to 20 Number o
62. CK JamAtOutTimer CHEGK VALUE 3000 mseec ADJUST VALUE Engin Value 22 Un expected Pack Exited Xfer Conveyor Purpose EVENT Inserter On Line Off Line Pack into Xcvy Sta 1 In Sensor to Pack into Xcvy Out Sensor EVENT CHECK Demand Feed CHECK VALUE 100 msec ADJUST VALUE Engineering Value 07 ANALYSIS Time exceeded Expected Pack Did Not Exit Xfer Cvyr Purpose EVENT Inserter On Line Off Line Pack into Xcvy Sta 1 In Sensor to Pack into Xcvy Out Sensor EVENT CHECK Demand Feed CHECK VALUE 100 msec ADJUST VALUE Engineering Value 07 ANALYSIS Time exceeded Jam Into Xfer Cnvy Station 1 Purpose EVENT HOPPERFILL Xcvy Clutch ON to Pack into Xcvy Sta 1 In Sensor EVENT CHECK IntoStation1 Timer CHECK VALUE 225 msec VALUE 100 Speed ADJUST VALUE Engineering Value 8 ANALYSIS Time exceeded Jam Out Of Xfer Cnvy Station 1 Purpose EVENT HOPPERFILL Xcvy Clutch ON to Pack out of Xcvy Sta 1 In Sensor EVENT CHECK OutOfStation1Timer CHECK VALUE 60 msec CHECK VALUE 100 Speed ADJUST VALUE Engineering Value 9 ANALYSIS Time exceeded D 6f 16 or 18xxx Reader nnz16 Bar Read Messages or nn 18 Line Read Messages Error Description nn001 GROUP NUMBER OUT OF SEQUENCE nn002 EXPECTED END OF GROUP 438 OPERATOR amp SERVICE MANUAL 071 28558 401 Cause Remedy The page that was just fed did not follow the selected group sequencing pattern If
63. ER CT 06412 JNLESS OTHERWISE SPECIFIED 438 AE TEL 860 526 9561 NEXT ASSY USED ON EN DMENSIONS ARE INCHES AND 005 TOLERANCE ANGLES 27 ORIGINAL APPLICATION DRAN WAZA Ven SCHEMATIC CREEPER CONTL MOTOR CHECKED REMOVE BURRS SHARP EDGES amp COR op m TION SIZE DWG ND THIRD LE PROJECTION ss v DR DN INTERPRET DRAWING PER ANSI Y145 FROM GBR SYSTEMS CORPORATION Groot 2 SCALE 4 4 SHEET 4 OF SIZE KS SEVISIUNS ZONE REV DESCRIPTION DATE APPROVED DRIGINAL RELEASE 9017 05 10 04 wfm L1 2 lt gt Lo 3 lt e gt GND IS 5 lt INHIBIT N AN SINGLE LEVE A Lu JA 3 i 3 EN ABLE e lt gt lt gt 6 PEED CDNTRDL GBR SYSTEMS CDRPDRATIUN FNSH H x m gt INSPIRATION LANE CHESTER CT 06412 UNLESS OTHERWISE SPECIFIED 438 EL TEL 860 526 9561 DMENSIONS ARE NCHES AND NEXT ASSY USED DN 00 ORIGINAL APPLICATION DRAWN W MAZZA 3 24 04 SCHEMA gt F Le DE X M R PE B C
64. EVISIONS ZUNE REV DESCRIPTION DATE APPROVED ORIGINAL RELEASE ECN 9394 08 15 06 E JH FEEDER UN a ORG rm uu 3RN gt BI gt ies I 3 i i WHT BRN RED n e RED 4 lt l BK E 3LK J nna BY x ML c PX k Tm jJ RED RED AAAA AAT gt REMOVE JUMPERS A TBS AS FOLDER INTERFACE MODULE 8 CUTTER T KICKER MODULE 10 MATL H Pyyn UYXXYIHUYYYXYHQYYYXXIHGYYYXXI Y YYYYYI UA ae LYYYYYYYYLYYYYYYI Y YYYYYI z GBR SYSTEMS CORPORATION a FNSH H Z 12 INSPIRATION LANE CHESTER CT 2 is 1 LI L OTHERWISE SPECIFIED 38B TEL 8 NEXT ASSY USED DN Wii TOLERANCE NS ARE IN INCHES ANGLES 27 ORIGINAL APPLICATION DRAWN E HARRIS 2 7 REMOVE BURRS SHARP EDGES amp CORNERS SIVE DWG ND THIRD Ah XE nud JTHORIZED TEN CONSENT SCALE 4 1 SHEET ry oF 5 01 f PER ANSI Y14 5
65. GO TO TABLE OF CONTENTS jg EE 438A Folder 438B Feeder V4 Service Manual ISSUE 2008 05 071 28558 401 A 438A SERVICE MANUAL ISSUE 2008 05 071 28558 401 A COVER PAGE 1 438A SERVICE MANUAL ISSUE 2008 05 COVER 071 28558 401 A PAGE 2 While every care has been taken in the preparation of this manual no liability will be accepted by GBR Systems Corporation arising out of any inaccuracies or omissions All service documentation is supplied to GBR Systems Corporation external customers for informational purposes only GBR Systems Corporation service documentation is intended for use by certified product trained service personnel only GBR Systems Corporation does not warrant or represent that such documentation is complete GBR Systems Corporation does not represent or warrant that it will notify or provide to such customer any future changes to this documentation Customer s service of equipment or modules components or parts of such equipment may void any otherwise applicable GBR Systems Corporation warranties If Customer services such equipment modules components or parts thereof Customer releases GBR Systems Corporation from any and all liability for Customer s actions and Customer agrees to indemnify defend and hold GBR Systems Corporation harmless from any third party claims which arise directly or indirectly from such service Prepared by GBR Systems Corporation Technical Publications Copyright 20
66. HECKED ANGLES e EDGES amp CO THIRD ANGLE PR UNAUTHORIZED R WITHOUT WRITTEN CONSENT SCALE 4 SHEET OF INTERPRET DRAWING PER ANSI Y14 5 SUM GBR SYSTEMS CORPORATION C 001 1 2 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 23 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 ELECTRONICS SECTION C PAGE 24 SIZE 2 2 SH POWER CIRCUIT Jo INHIBIT NTR SINGLE LEV J3 SPEED CONTROL Le REVISIONS ZONE REV DESCRIPTION APPROVED ORIC INAL RELEASE ECN 9017 MATL FNSH H UNLE DMENS AN D ANGLES 2 REMOVE BUR ES TOLERANCE EDGES amp COR SE SPECIFIED l nd N INCHES NEXT ASSY USED UN GBR SYSTEMS 12 INSPIRATIU E TEL 866 N LAN CORPORATION CHESTER CT 06412 526 956 ol ORIGINAL APPLICATION DRAWN W MAZZA THIRD ANGLE ZAR D INTERPRET DRAWINC NIR SCHEMATIC bs PER ANSI 145 DWG N
67. ICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 6 3 C 3 E STOP amp INTERLOCK BOARD ASSEMBLY The two boards shown on this page are connected together to make one assembly and although these boards can be separated into two separate assemblies it is recommended that the board with the relays on it be replaced as a complete assembly including all relays should it become necessary The relays on the board are connected in such a way that it is difficult to troubleshoot and the assembly is a protection device to prevent harm to individuals during the machines operation The assembly s location is inside of the top of the DC Power Distribution Chassis Assembly Shown on page 5 of this manual C 4 COMPUTER CHASSIS ASSEMBLY 196 31487 500 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 Power Supply 5 12 amp 12 520 ceu RH Ww ELECTRONICS SECTION C PAGE 7 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 8 C 4a CPU Controller SAT 520 C 4b Video I O up to 4 Serial inleiace RS232 Ports two em drive interface Internet and LPT1 Port General Description SAT 520 Daughter Card installed as 2 x 48 I O two cards stacked Description of Ports or 1 x 96 I O 1 Access panel for Line Read BCR Com Ports The I O 96 card is responsible for the Input Output interface between
68. Insertenr Setup O a u in PeronrepP UP Insert r Setup 1 5 eene e etre T is Ak lt Ins rt r Setup ier DEGERE ES A 71 Inserter Setup 324 eese oce o RERO P eR EO ua A 71 Insertet Set p 3 cete aM FE ETE Am Inseiter Setup 4 esce ctn DD pee ee ee a Reno Engineering Values Password Protected AK JEXitC omni ceste e NOT tei e ete E un 438 V4 OPERATOR amp SERVICE MANUAL 071 28558 401 A 8 ENGINEERING VALUES aa aaa teens tnt 28 A 9 LINE CODE READ SYSTEMS OPTIONN 32 I 1 9 Introduction iuuenes eedem etiem dena dA A 9b 438 Line Read Setup Screens GBR amp 32 2 A 9b 438 Line Read Setup Screens GBR amp 33 9 Line Read Setup L eie nensem ete eerie 33 2 AOd Line Read Sep 2 had kna a ay anaes 36 Ae Lane Read Setup 92 saan sasina d utere 39 2 AcOEt Pine Read 41 10 LASER BAR CODE READ OPTION 42 A 10a Laser Satety epe 42 7 A 10b Bar Code sende ROD Rud 42 A 10c Adjusting Your MS 911 sse 43 A 10d Setting the 438 to Read Laser Bar Code 44 9 A 10e Bar Read Setup Luya
69. Jg9 4 31930 3114 SEVISIUNS ZONE REV DESCRIPTION DATE APPROVE ORIGINAL KELEASE ECN 9394 08 15 06 EJH MODULE 2 AE m TER 7 FOLDER 24V RET 12218 A RED T gt zl ED 5 RED WHT z WHT GRN CRN i ORG 2 BLU D 2I FOLD FOLDER EXI FOLDER YEL 142 lt TAN OUTPUT SHINGLING RED GRN x RED CRN INTER INTER RED YEL RED YEL BLK RED BLK E WHT BLK BLK ACCUMULATOR JMP CLUTCH GBR SYSTEMS CORPORATION 12 INSPIRATION LANE CHESTER CT 06 TEL 2961 13 NEXT ASSY USED ON TITLE ORIGINAL APPLICATION REMOVE B
70. K YEL B 21 BRN Vm uet et 1 Sq SENSOR j BLU DEMAND Kis lt a XL O c g lt WHT BLK 17 lt RED i 2 2 18 4 ROME ED gt INTERLOCK ED RED 3LK BRAKE iU CLUTCH 3LU sol MATL e GBR SYSTEMS CORPORATION s FNSH d H 7 3 EOS 2 INSPIRATION LANE CHESTER CT 06412 lt UNLESS OTHERWISE SPECIFIED 438B x DMENSIONS C E TEL 860 526 9561 S ARE IN INCHES NEXT ASSY USED EN k C 5 TOLERANCE SITE ANGLES 2 ORIGINAL APPLICATION DRAWN E HARRIS ecu REMOVE BURRS SHARP EDGES amp CORNERS THIRD ANGLE PROJECTION SUE DWG NO CHECKED INTERPRET DRAWING PER Z BI 597 31570 312 i REVISIONS ZUNE REV DESCRIPTIUN DATE APPROVED ORIGINAL RELEASE ECN 9394 08 15 06 EJH FEEDER Ee 4 0 O4 START STOP EI o lt RED WHT igi WHT 7 5 CYCLE INTERLOCK Sce RESET AN m ees O O gt E STOP
71. KED INTERPRET DRAWING PER ANSI BLE ED D HEREIN TRANSMITTED TO ANY UNAUTHORIZED ERSUN OR ORGANIZATION WITHOUT WRITTEN CONSENT Y145 FROM GBR SYSTEMS CORPORATION 001 d 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 ELECTRONICS SECTION C PAGE 31 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 ELECTRONICS SECTION C PAGE 32 SUE DWG NO zs 2 5 REVISIONS ZUNE REV DESCRIPTION DATE APPROVED DOUBLE DETEC FOLDER EX SENSO ACCUM oc 8 J 4 a ORIGINAL RELEASE 9394 08 15 06 EJH TE amp INTERCONNECT i S 5 JU ARD a MOD 2 oe MOD S 4 SE MOD 41 4 D 100 4 i a 100 6 LI T MATL FNSH GBR
72. L EUER EE GBR SYSTEMS CORPORATION 24 INSPIRATION LANE CHESTER CT 06412 ESS OTHERWISE SPECIFIED A38B EA TEL 860 526 9561 IONS ARE IN INCHES VERTES TE 860 526 956 NEXT ASSY USED DN re TITLE ORIGINAL APPLICATION se lt N POR SCHE DISTRIBUTION PCR E HARRIS C1 REMOVE BURRS SHARP m ELECT EDGES amp CURNERS THIRD ANGLE SIE SSTA LARA tus Needs THE GBI B 3 5 OUT 300 AND MUST NOT BE RI PERSON ORC SCALE SHEET OF 2 INTERPRET D C v145 FROM GBR SYSTEMS 1d 1 an L T BI 196 30500 300 INHIBIT ENABLE J3 SPEED ONTROL SEVISIONS REV DESCRIPTION APPROVED ORIGIN AL RELEASE 9017 05 10 04 wfm ED DC WAS BLK ECN 9150 12 09 04 AN AN s gt TAN lt Lt ug s Lp gt TAN See gt vI e lt LIN FILT CIRCUIT BOARD 30502 500 NTROLLER s oS s 6 gt 2 BLK Bos MATL eee GBR FNSH A3 UNLESS OTHERWIS 320 D
73. MENSIDNS ARE USED ON SYSTEMS 12 INSPIRATION LANE TEL CDRPDRATIUN CHESTER CT 064102 860 526 9561 ORIGINAL APPLICATION DRAWN W MAZZA 3 24 04 CHECKED APVL INTERPRET DRAWING PER ANSI Yl4 5 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 ELECTRONICS SECTION C PAGE 21 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 22 Bl 196 30501 300 REVISIDNS ZUNE REV DESCRIPTION DATE APPROVED ORIGINAL RELEASE ECN 9017 05 10 04 wfm A A WAS A A WAS A ECN 9050 12 09 04 wen m gt L gt TAN eu x LINE nw US TAN lt lt uel gt FILTER gt 122 711 oe INHIBIT lt gt GND gt ERN lt lt CHASSIS gt 3 gt CREEPER MOTOR CONTR PRINTED CIRCUIT POARI DET MEER di KATAR pw pu F ces ENABLE lt SPEED CONTROL pep s Pes BLK nse I GBR SYSTEMS CORPORATION ss 12 INSPIRATION LANE CHEST
74. NUAL ISSUE 2008 05 REPAIR INFORMATION 071 28558 401 SECTION D PAGE 21 438 OPERATOR amp SERVICE MANUAL 071 28558 401 nn018 nn019 nn020 021 022 023 024 025 026 ISSUE 2008 05 REPAIR INFORMATION SECTION D PAGE 22 INVALID SETUP DATA Reader board memory corrupted PARITY ERROR computed in action REGISTRATION BAD BAD ON CHIP 8501 RAM INVALID READER ERROR INVALID CAL SETUP NO BANK 2 GATE MARK Restart machine Actual lines of codes must match parity setting odd or even Bad code OMR Linecode marks are out of tolerance or the spacing is inconsistent Bad code Hardware failure on reader board Battery failed or battery jumper missing Bad CPU 186 board CPU does not understand reader Feed through calibration sheet several times to ensure that encoder is reading properly consistent read numbers Reader encoder bad Reader was expecting two sets of read code one was missing Reader set up improperly Code is physically missing Check to see that the proper barcode job is selected computed in action CALIB OUT OF RANGE Calibration failed YES NO EOG ARE SAME Check calibration sheet Check read setup again particularly focus Check for correct feed speed Check speed sensor for proper operation This error is only associated with European machines Check read setup again particularly focus Check for correct feed speed Che
75. Position STA 6 stations after envelope insert station e 2 Enter Point Option PT 2 Select Station 8 Postal Meter Weights e 99 Meter 1 to 2 Weight Value e 20 Meter 2 to 3 Weight Value Notes A 14 Weight Values are 5 digit numbers of arbitrary dimension Be consistent use tens or hundreds of an ounce or gram for all values The maximum allowable internally computed package pages envelope inserts total value is 64000 Meter Output Point Option selection locks out standard operation of the output selected i e Station 7 Select selection does not allow standard Inserter Station 7 select through reading Choose another Meter Output Point to resolve conflicts with actual installations All meters are positioned at the same Station This is the station after the last index track station of the inserter The number is counted from the Envelope Insert Station of the inserter Factory testing has shown that the pack moves out of the last index track station between 200 and 350 degrees Meter enable imprint is timing is based on the ON AT degree for each meter The first meter in line tested at 200 degrees The second meter inline required some delay and was tested at 240 degrees At higher speeds packs imprinted with the first meter inline were mistakenly being imprinted by the second meter inline unless its ON AT degree was slightly delayed SOFTWARE UPDATES VIA EMAIL The disk for this pro
76. Side View Ex gj P e Ca Z 7 D i B eA 4 he A E gt d b x9 vw 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 INTRODUCTION 071 28558 401 SECTION A PAGE Layout of Model 438 V4 Top View 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 INTRODUCTION 071 28558 401 SECTION A PAGE 4 A 3a Feeder Section 438 V4 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 Feed Belt The Main Feed Belt is a one inch wide beige timing belt which drives the bottom sheet of paper under the singulator roller Also called Singulator Belt Auxiliary Feed Belts These are two urethane belts located either side of the main feed belt The auxiliary feed belts assist the main feed belt smoothing variations in fri
77. Singulator N 4 x x 4 Singulator Adjust Knob 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 INTRODUCTION 071 28558 401 SECTION A PAGE 6 A 3b Accumulator Section The accumulator is fed paper from the singulator assembling groups of one to seven documents When the document package is complete it is fed to the folder Stacking Ramps Stacking Ramps are the plastic wedges which position successive pages of a h i pn lt Stacking Ramps E Co y configuration document package in order Stacking Rollers These are used to stop the paper and hold it in position When released the Stacking Rollers drive the collected pages out of the accumulator Dump Brake This prohibits the rollers from releasing paper from the accumulator Dump Clutch This activates the stacking rollers releasing the accumulated pages 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 Accumulator Sensor The Accumulator Sensor indicates presence or absence of a package in the accumulator It also monitors package discharge when the dump clutch has been engaged Stack Sensor Located at the edge of the ramps the stack sensor indicates
78. TERING GBR 438 420T Postal Meters and Postal Meter Weight Calculation January 30 2006 File g iso9000 manuals operator amp service 438ab service manual 071 XXXXX 400a 2006 04 service not released info on postal metering on 438_420t 7 27 06 doc Page 51 of 55 Overview This document outlines the setup of the Postal Meters Weight Calculation and Operation of Postal Metering on the GBR 438 420T Note The order of postal meters to weight was reversed at 26412 044 on the GBR438 e GBR 420 and GBR438 420T prior to 26412 044 Aug 2001 e LOW to High Postal Meter 1 to Postal Meter 3 e GBR438 420T after 26412 044 Aug 2001 e HIGH to Low Postal Meter 1 to Postal Meter 3 to allow Postal Meter 1 Postal Meter Divert to divert an over weight size package first before the meters Note Revised from the GBR 438 document n4wght1 doc Installation e The Postal Meter kit uses existing Input Output IO points in the GBR438 and an existing cable kit and normally operates e Postal Meter Divert Test point Postal Meter Divert Rack1 Point19 is Postal Meter 1 PM1 e Select Station 7 Test point Separation Sol 7 Rack1 Point4 is Postal Meter 2 2 e Select Station 8 Test point Separation Sol 8 Rack1 Point6 is Postal Meter 3 PM3 e f you use Stations 7 and 8 there are alternate IO points that can be used call the factory e In general the Postal Meters are driven by 24VDC 3AMP output modules 24VDC power general
79. TY DF M gt se T ctt e gt IS RETURNABLE UPON 5 JQ3 OPH U 3Ur INTERPRET DRAWING PER ANSI Y14 5 s gt gt SUE DWG NO 4 REVISIONS ZUNE REV DESCRIPTION DA TE APPROVED ORIGINAL RELEASE ECN 9394 08 15 06 EJH EFE EIE YYYYYYYYYYYY X6 E STOP MATL dt E READER DOC OY Y Y Y Y Y FNSH GBR SYSTEMS CUR UNLESS DTHERWISE SPECIFIED DMENSIONS ARE IN INCHES AND 005 TOLERANCE ANGLES 2 REMOVE BURRS SHARP EDGES amp CORNERS A38B NEXT ASSY USED ON ORIGINAL APPLICATION TEL 860 526 12 INSPIRATION LANE CHESTER CT 06412 P ORATION 9561 DRAWN E HARRIS 2 7 2006 CHECKED THIRD ANGLE PROJECTION f CIN VS INTERPRET DRAWING PER ANSI Yl4 APVL NI ELI DOWER DISTRIBUTION CABINET PERTY DF GBR SYSTEMS LE UPON REQUEST UR THE INFORMATION ANY UNAUTHORIZED N CONSENT WING IS THE ION IT IS RI NI L 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 ELECTRONICS SECTION C PAGE 27 438 OPERATOR amp SERVICE MANU
80. Transfer Conveyor Discharge Sensor and Module used in a stand alone configuration This monitors the discharge of paper packages from the output conveyor It Transfer Conveyor 8 5 and 11 versions acts to confirm the processing of specific documents Transfer Conveyor Package Presence Sensor and Module ITEM DESCRIPTION 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 INTRODUCTION 071 28558 401 SECTION A PAGE 9 A 3e Emergency Stop Interlocks The main E stop located on the operator panel will interrupt power to the conveyors and folder when pressed down This switch must be twisted to bring it back to its original upper position An extra contact is provided on this E stop switch which is routed to pins 30 and 33 of the Inserter Connector located on the adaptor plate on the end of the cabinet This will affect an E stop to an external device when these contacts are wired to the E stop circuit on that external device e g Pinnacle A connection to the 438 interlock string has been provided on pins 28 and 29 of the same Inserter Connector which allows an external device e g Pinnacle to E stop the 438 For this E stop string to be functional a blue jumper across pins 24 and 25 of Module 7 on the I O Board must be removed If this E stop string is not used this jumper must be in place Pin 11 of this connector also provides an Interlock Sense signal to an external device
81. U L SIZE DWG NO 4 SH SUPPLY SEVISIUNS ZONE REV DESCRIPTION APPROVED ORIGINAL RELEASE ECN 9394 EJH FLATS FOLDER N U A AI L as 4 5 E ALTE JISTR 3U TION KATAN MATL FNSH 4381 NEXT ASSY USED ON X 2 7 12 GBR S T STEMS INSPIRATIUN LA EL 86 CORPORATION CHESTER CT 06412 026 9561 ORIGINAL APPLICATION DRAWN E HARRIS 2 7 2006 REMOVE BURRS SHARP EDGES amp CORNERS RIBUTI THIRD ANGLE PROJECTION a AN X J NL INTERPRET DRAWING PER ANSI Y145 WITHOUT SYSTEMS CORPORATION t 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 ELECTRONICS SECTION C PAGE 25 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 26 REVISIDNS ZUNE
82. Weight is default INTRODUCTION SECTION A PAGE 48 GBR Systems Bar Read Setup 4 ReadFeed Type v Feed amp Read Read amp Feed Read amp Feed Start Delay 0 t Cust ID Seq Same ID Matching Off Customer ID Code Start 10 Length 10 l l Code Lengths Code39 0 I20f5 0 Code128 O 1 1 l I l Number Reads Num Reads 0 l Process Status Cancel Ready A 10i Bar Read Setup 4 ReadFeed Type Feed amp Read When it is desired to Feed first and then Read normal Read amp Feed When it is desired to Read before Feed In cases where the EOG end of group must be known before feeding next page Read amp Feed Start Delay Only used with Read amp Feed and it is to delay the read to let the previously fed document get clear of the feeder Cust ID Seq Same ID Code group matching between sets Matching Code group matching only within a set Off disables code group matching Customer ID Code Start Customer number group ID or other number can be found beginning with this character in the Bar Code Length Number of lines after the start i e start 6 length 3 From the gatemark the start is found at line 6 and the length is line 6 7 and 8 Code Lengths 1 disables reading in each category 0 enables reading with variable length and any number indicates length e g Code 39 with a length of 6 a code block with 6 characters Code 39 3 of 9 Bar Code 12 of 5 Interleave
83. achine speed sample being done LED3 ON indicates line codes will be read using calibration data that has been stored OFF indicates line codes will be read without using calibration data that has been stored LED s 1 4 are all turned on while the boot functions are being done All the lights will stay on if a problem is detected in the hardware of the line code reader card LED5 Input of lead edge detection sensor probe 1 sensing paper LED off LED6 Input of lead edge detection sensor probe 2 sensing paper LED off LED 7 Not used LED8 Input of selected line code sensor Probe 1 or Probe 2 C 9 LINE CODE READ CHASSIS 0402005094 E Read Interface Panel Solder Side Mr 042 30445 500 14 01 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 13 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 The previous page contains various photos of the line read chassis assembly components The housing is mounted to the top of the SAT 520 CPU housing Top right is a picture of the housing with the cover removed and the read card slid out for a better view Across the rear of the housing is a connector soldered into the backplane which mates with the read card In the lower left of the page is a picture of the backplane and the power connector The red wire is 5vdc and the next black wire is 5vcom The yellow wire is 12vdc a
84. ariations If the Feed Belt is replaced 1 Loosen the long set screw 3 32 on the top stop collar 4 a of the feed belt tension knob shaft 2 Lay a straight edge across the top of the feed belt lengthwise Make sure it lays across both pulleys 3 Adjust the feed belt tension knob so 3 16 inch feed belt deflection is possible in the middle of the belt Now turn the tension knob 3 8 turn CCW Slide the stop collar to the top of the tension knob shaft Position collar so the long set screw is perpendicular to the side frame Tighten set screw to the tension knob shaft This will again limit adjustment to 3 4 turn Singulator and Paper Demand Ag WAN FEED ADJUSTMEN Belt Adjustment Figure Singulating Roller The singulating roller creates a precise singulating gap There are three critical adjustments required to get a precise singulating gap These adjustments are Vertical position of singulating roller Singulating roller parallel with lower rollers Occasional rotation of singulating roller Position of Singulating Roller The position of the Singulating Roller with respect t
85. ays the package demand rate from the inserter Calculated at every demand signal transition not averaged e Date and Time not functional at this time EOG Displays end of group ready for dump e Group Displays group sequence number after read e Page Displays page sequence number after read e Total Diverts Displays the number of diverts since the start of the run e Batch displays Batch Sheet or Batch Package count resets on sequential stop e Insert Marks Displays which insert are selected after each read Control Marks Displays any controls marks such as IM Ink Mark after read e Diagnostic Internal timing e Monitor Events Displays event history however entire list is lost when power is turned off 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 INTRODUCTION 071 28558 401 SECTION A PAGE 13 CYCLE PURGE RESET zB 48 IO A 6 KEYBOARD OPERATION START STOP Press to start all motors and enter ready mode Press while in ready mode to shut down the 438 CYCLE Press quickly to feed one sheet Repeat until EOG on display is 1 DUMP Press and hold CYCLE to start continuous feeding PURGE Press after manually filling the accumulator to discharge package into the folder 438 V4 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 RESET Press after interlock
86. ck rubber belts driven by a motor located on the bottom side of the hopper Controlled by a paper level detector the motor is activated when the detector indicates that paper is low 438 V4 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 Hopper and Feeder Paper Guide Rails The two stainless steel rails mounted on the hopper are adjustable via a locking handle at the rear At the front they interlock with the feeder side rails then lock to shafts running across the machine Both sets of rails should be adjusted together Paper Hopper The Paper Hopper supplies the bottom fed friction feeder continuously while the operator loads paper from the top It has 4 mounts 2 each side with set screws in which the hopper slides The Hopper Table is located behind the feeder Paper level in the hopper is controlled by a demand switch The position of the hopper table determines how well the demand switch will perform this function During normal operation a metal wand rests on the incoming paper As more paper is needed the metal wand will fall low enough to close the demand switch This activates the creeper conveyor motor to drive the hopper belts conveying paper into the feeder area under the paper level detector When the proper level of paper is attained the wand will have been lifted enough to open the switch shutting off the creeper conveyor motor INTRODUCTION SECTION A PAGE 2 Layout of Model 438 V4 Operator Left
87. ck speed sensor for proper operation Check for failure on the CPU replace as necessary Bad UARTs Bad software nn027 028 029 nn030 nn031 nn032 nn033 nn034 nn035 nn036 nn037 nn038 ROLL PAGE OUT OF SEQUENCE UNEXPECTED RESPONSE EXPECTED READING READER REBOOTED computed in action CALIB IN RANGE NO RANDOM CHECK MK UNEXPECTED RANDOM CHECK PACK LARGER THAN SET PACK LESS THAN SET GROUP NUMBER CHANGED IN SET LAST SET SAME GROUP NUMBER MAX SHEETS IN ACCUM 438 OPERATOR amp SERVICE MANUAL 071 28558 401 The page that was just fed did not follow the selected roll sequencing pattern If the roll is not out of sequence check to see that the proper barcode is printed on the page and that the barcode matches the specifications Check to see that the proper barcode job is selected Paper jam Reader board failed Reader encoder bad Blank page Read encoder failed Paper jam Feed sensor out of adjustment Reader encoder failed Bad read board Calibration was successful Incorrect document in accumulator Random check mark not set correctly in Setup Code bad or misprinted Incorrect document in accumulator Random check mark not set correctly in Setup Code bad or misprinted There were more sheets in the package than expected There were less sheets in the package than expected Every page within a set is supposed to have the same
88. code print on the paper is good quality Incorrect page count in accumulator Page count setting incorrect EOG mark not seen Read error Incorrectly printed document Documents out of order Code not seen Check clean and adjust scanner Check digit in code is wrong Code not seen Check clean and adjust scanner Documents in package exceeded the max sheets expected Page out of sequence Incorrectly printed document Documents out of order Code not seen Check clean and adjust scanner ISSUE 2008 05 REPAIR INFORMATION SECTION D PAGE 25 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 D 6g 17xxx Inserter Error Messages Error Description Currently no error messages for this module D 6h 19xxx EngValue Error Messages Error Description Currently no error messages for this module D 6i 20 EXITCOMM Error Messages Error Description 20001 No Message Response A message was sent to an exit device i e Inserter the exit device did not respond D 6j 21xxx InFeed Error Messages Error Description 21801 Paper Demand Timeout EVENT Paper Demand Switch ON to Paper Demand Switch OFF EVENT CHECK PaperDemandTimer CHECK VALUE 20000 msec ADJUST VALUE Engin Value 17 ANALYSIS Time exceeded 21001 Paper Demand Timeout REPAIR INFORMATION SECTION D PAGE 26 A demand for paper was sent to infeed device i e Feeder paper was not detected by the feed senso
89. ctional drive correcting erratic feeding of the paper Drive Rollers These two orange rollers are located directly below the singulator These are used in conjunction with the singulator to ensure only one sheet is fed at a time Paper Level Detector This demand switch monitors the paper going into the feeder area Its job is to limit and demand the amount of paper that is most productive to the feeding process The Paper Level Detector monitors the paper through a metal wand Feed Sensor The Feed Sensor monitors the output of the singulator for proper singulation or non feed of paper The sensor module is located next to the double detect sensor in the singulator area Double Detect Sensor The double detect sensor is ultra sonic sensor which does not require electrical adjustment The mechanical position of the sensor is 40mm above the mounting plate 2mm The sensor determines that two sheets have been fed by a field induced between the two pages Feeder Speed Encoder A blue clad optical encoder located on the right side of the upper pullout shaft It is used to detect feeder run speed Feed Clutch Electrical clutch which engages the feed belt at a signal from the controller Read Sensor A through beam sensor located on the reader bracket which is mounted to the crossbar A reader logic board interprets variation in light intensity as it is reflected off the paper and code marks INTRODUCTION SECTION A PAGE 5
90. d 2 of 5 Bar Code Code 128 Number Reads Num Reads the number of times the reader should scan and take average to ensure good read poor printing can sometimes be a reason for multiple reads 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 INTRODUCTION SECTION A PAGE 49 A 12 READ ZONE DIAGRAMS APPROVED FOR P00 wa GBR SYSILMS iL V REVISION ON REV DESCRIPTIO DATE APPROVE kit zl ORIGINAL RELEASE FCN XXXXX r 25 8 L 1 28 S 2 5 2 RECOMMENDED i IN TOP 1 3 0 OPTIMA Bu LINE 4 READ ep SUN 25 25 25 31 37 f 12 INSPIRATION LANE CHESTER UNLESS OTHERWISE meats je SBIPRSIORS ARE IN T a EL 860 526 M ES 005 USED T rm r3 rm READ ZONE B amp H LINE REMOVE BURRS E SIDES amp CHECK AV 97 DWG g merata an UA 088 28255 Ec n Pr Sewn dat INTERPRET DRAWING PIR sins ommi i Q m ia E 1 REVISIONS READ ZONE THONG 88 7t 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 INTRODUCTION SECTION A PAGE 50 A 13 POSTAL ME
91. d all preceding Setup 2 must be performed first 3 Select Calibration On 4 Press OK 5 Now feed a single Calibration document on the machine 6 If none of the following errors are declared when a calibration document is fed the Line Code Recognition system is calibrated for the current selected Line Code spacing Errors Indicating A Bad Calibration e NOFEED e MARK DETECTED e MARK DETECTED IN 2ND BANK e CALIBRATION OUT OF RANGE 7 Ifa bad calibration is indicated RECALIBRATE must be selected before another Calibration document is fed Go back to step 4 INTRODUCTION SECTION A PAGE 37 Tolerance Use LOW setting unless there is not a good contrast between the document background and the function marks The LOW setting will tolerate some drift in the printer registration Use of the HIGH setting does not allow drift in the printer registration The mark location is very critical if the HIGH setting is used Use it if the contrast between the document and the function marks is poor The Line Code Recognition system supports two print line windowing schemes when interpreting a Line Code The two windowing schemes are High tolerance and Low tolerance reading Having two windowing schemes permits service personnel to select the windowing scheme which is best suited for the customer s application When Low Tolerance read is selected the print line windowing scheme used does not detect
92. d the the belts feeding of paper becomes erratic The auxiliary feed belts would be adjusted when the gap between the fed sheets needs to be MAN ED BL improved Raising the auxiliary feed belts will decrease the gap lowering the belts will increase the gap uU E um inr MAIN FEED BE 9 rl Lm LH r AUXILIARY FELD BELTS Feed Belts Figure 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ADJUSTMENTS amp REPAIR INFORMATION 071 XXXXX 400 SECTION E PAGE 7 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ADJUSTMENTS amp REPAIR INFORMATION 071 XXXXX 400 SECTION E PAGE 8 Sensor Adjustments The picture below shows both the Double Detect and the Feed AII of the paper detecting sensors on the 438 are Retro Sensor as located in the Feeder section on the GBR Friction Reflective digital sensors Each sensor has its own amplifier unit Feeder and requires no adjustment ULTRASONIC DOUBLE DETECT SENSOR h i gt 7 Use only this style reflector E 2 ACCUMULATOR SECTION E 2a Description Fed by the feeder section the accumulator is used to group up to twelve documents before it sends them to the folder Wedge shaped stacking ramps position pages sequentially Stacking rollers are used to stop the paper and hold it in position When released the stacking rollers drive the collected pages out of the accumulator The Dump Clutch activates the stacking rollers releasing the accumulated pag
93. d to be sure all pages within each pack have identical group sequence marks NONE No group sequence The purpose of the Group Seq mark is to ensure pages from two different packages do not get processed in a single package Group Seq marks must be present when using GROUP SEQUENCING PAGE SEQUENCE PAGE UP Choose if the page is counted UP 1 2 3 4 PAGE DOWN Choose if the page is counted DOWN 4 3 2 1 ROLL UP Cycle counts up sequentially to a selectable value set in Line Read Setup 3 Group Seq and Page Seq Min and Max ROLL DOWN Cycle counts down sequentially from a selectable value set in Line Read Setup 3 Group Seq and Page Seq Min and Max ITEM COUNT Choose when the first sheet in a package indicates the total number of sheets in that package Total Up Linked to total page count this will expect the pages to count up during each pack feed Total Dn Linked to total page count this will expect the pages to count down during each pack feed NONE No page sequence There is a limit of three Page Sequence marks Their purpose is to give an individual identity to each page within the package The maximum number of pages in a package is seven Page Sequence marks must be present when using PAGE SEQUENCING 438 V4 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 Parity Mark Odd Parity Counts the total number of marks read If the total is an odd number then the parity test is passed If the
94. ded NOTE If physical paper jams re occur and mechanical adjustments are correct escalate service Potential trouble spots are numerous but include worn or damaged parts stretched drive belts excess static SECTION D PAGE 4 Verify all cable connections are properly mated and all applicable sensor connections as per application are mated properly and not obstructed In SETUP verify that correct input parameters are selected Verify the Emergency Stop button is not actuated e Twist to reset e Press RESET blue switch D 4 TEST SCREEN OPERATION Diagnosis of the system begins with these tests If it is found that the displayed information indicates a problem refer to the schematics in section D or section F GBR Systems Test 10 144 Test List Board Cycle Errors Feed Speed Fold Speed o Speed Read Speed 0 Diagnostic Events 10 07 01 Comm lib 2 0 2004 04 16 Built Mar 25 2005 16 54 11 1 10 07 01 lo lib 2 0 2003 08 04 BuiltMar 9 2004 16 13 59 m 10 07 01 Isr lib 2 0 2003 09 03 Built Mar 9 2004 16 07 52 10 07 01 Lnrddev lib 2 0 2003 08 04 Built Sep 8 2005 14 52 36 10 07 01 Mcmio144 1ib 2 0 2003 08 04 Built Mar 9 2004 15 59 15 10 07 01 Misc lib 2 0 2003 08 08 Built Mar 9 2004 16 10 14 10 07 01 Rd lib 2 0 2005 05 17 9 2005 11 45 36 10 07 01 Util lib 2 0 2003 08 04 Built mar 9 2004 15 54 38 10 07 01 Vga lib 2 0 2003 08 04 built May 20 2005 16 26 44 10 07 01 Wwin lib 2 0 2003 08
95. duct is specifically bootable on the 438 This boot software is not normally visible and cannot be copied from one disk to another The entire disk must be disk copied or copy disked 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 The application software GBR420 exe is visible and can be copied to and from an e mail another disk or from the hard disk of a computer PROCESS 1 Attached to the New438 426 420T is a new revision GBR420 exe Save this and any other files to your hard disk in a unique folder such as gbr 29101005 where 29101 is the part number and 005 is the current engineering revision number Make a disk copy of your current master In Windows Explorer or My Computer right click on the 1 2 Floppy A and Copy disk your current master to a new 12 disk Copy the new e mailed software revision executable GBR420 exe to the new disk from step 2 Overwrite the previous revision Copy any other files sent such as the dictionary msgs420 dat to the appropriate place on the new disk such as gbr msgs420 dat This is the new master for the new revision Make a disk copy of this new master to another 1 2 disk Use this copy as the machine boot disk INTRODUCTION SECTION A PAGE 55 SECTION B PREVENTIVE MAINTENANCE B 1 Test equipment and tools 1 B 2 General procedures 1 B2 a CLEANING THE MACHINE 1 B2 b LUBRICATION 2 B 1 TEST EQUIPMENT AND TOOLS
96. e Enter Meter ON AT in degrees 0 to 350 After 90 degrees e Enter Meter OFF AT in degrees 0 to 350 Before 90 degrees e Enter Meter Position STA e to 12 after envelope insert station e 0 to disable this meter e Enter Meter Output Point Option PT e 1 Station 7 Select e 2 Station 8 Select DEFAULT e 3 Inserter E Stop e 4 Station 1 Error e 5 Station 7 Select Inverted Signal e 6 Station 8 Select Inverted Signal e 7 lnserter E Stop Inverted Signal e 8 Station 1 Error Inverted Signal e 9 Postal Meter Divert DO NOT USE e 10 Inverted Postal Meter Divert DO NOT USE e 11 Moistener e 12 Moistener Inverted Postal Meter Weights e Meter 1 to 2 Weight Value 00000 to 60000 e Meter 2 to 3 Weight Value 00000 to 60000 Weight Page and Envelope e Enter Page Weight Value 00000 to 60000 e Enter Envelope Weight Value 00000 to 60000 Weight Inserts 1234 e Enter Insert gt 1 Weight Value 00000 to 60000 e Enter Insert gt 2 Weight Value 00000 to 60000 e Enter Insert gt 3 Weight Value 00000 to 60000 e Enter Insert gt 4 Weight Value 00000 to 60000 eS ware aT wa INTRODUCTION SECTION A PAGE 52 Weight Inserts 5 6 7 8 e Enter Insert gt 5 Weight Value e Enter Insert gt 6 Weight Value e Enter Insert gt 7 Weight Value e Enter Insert gt 8 Weight Value 00000 to 60000 00000 to 60000 00000 to 60000 00000 to 60000 lt lt rae ware SO Weight Calculation Postal Meter Selection
97. e Fluke Scope Meter e Standard amp Metric Hex Wrenches e SmallBlade Flat Screwdriver e Philips Head Screwdriver B 2 GENERAL PROCEDURES WARNING DO NOT ATTEMPT TO CLEAN THE 438A WHEN THE MACHINE IS RUNNING ATTEMPTING TO DO SO COULD RESULT IN INJURY BE SURE THAT MACHINE POWER IS OFF AT ALL TIMES WHEN CLEANING B2 a CLEANING THE MACHINE The 438 should be cleaned daily to remove any dirt or dust that may interfere with the operation of the machine Paper dust collected in motion areas could impede and or damage integral parts of the folder Paper dust can also obscure the read image reducing a quality read if it accumulates on the read head Excess dirt or toner build up from laser printing on the feed belts could result in damage or marking to the material and or premature wear of the feed belts Therefore it is important to perform the following daily cleaning instructions 1 Clean ALL Feed Belts 2 Remove ALL Paper Dust by vacuuming using a small clean paint brush is most effective Using compressed air to clean the machine may drive the accumulated dust into hidden areas of the machine that are not easily accessible resulting in increased wear and wicking of vital lubricants 3 Clean the Fold Rollers 4 Clean the Machine Cabinets and Covers B2 a1 Cleaning the Fold Rollers All accumulated paper dust should either be brushed or vacuumed from the 438 Clean all accumulated paper dust from the electronic paper sens
98. eck it is at the first perpendicular point The gripper arm continues to move out away from the track and reverses direction The inserter is now 180 degrees in its cycle With the gripper arm continuing to return toward the insert hopper it will again come to a position perpendicular to the deck This is the correct point to have the demand switch send a signal to the GBR There is a large window of opportunity here that is about 110 degrees wide A signal from the demand switch within the window will tell the GBR it is time to place a package in the track and this can be adjusted by rotating the demand block for optimum performance 438 OPERATOR amp SERVICE MANUAL 071 XXXXX 400 ISSUE 2007 09 This timing setup is also used to adjust dwell time for the Open Feed option Move Closer To Increase Duration To PF300 Folder Magnets Slide To Change gt Duration Magnetic Reed Switch Magnet Block Block Rotate For Proper Timing X 1 Pack Length D Point at which gripper arm takes pack Demand switch turns ON 8 Demand switch turns OFF Transfer Conveyor Demand Switch Figure ADJUSTMENTS amp REPAIR INFORMATION SECTION E PAGE 29 438 OPERATOR amp SERVICE MANUAL 071 XXXXX 400 E 4c Exit Sensor Test on the Transfer conveyor The exit sensor on a 438 creates an interrupt to the control card This interrupt permits accurate positioning of packages on the transfer conveyor Testing the inte
99. ed Read Clutch is off at lead edge of page on after read received Pulse Feed Time Use when Timed is selected Higher the number the larger the gap between sheets INTRODUCTION SECTION A PAGE 17 A 7c Accumulator Accumulator Max Select up to 12 sheets maximum the 438 will shut down on the 13 sheet fed into the accumulator This function prevents damage to the folder 12 may be selected when it is not desirable to have a package split into subsets The 438 will still shutdown on the 13 sheet The operator must clear the accumulator and manually process the package Accumulator Type Flat or Normal 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 GBR Systems Accumulator Setup Accumulator Max Sheets 12 Accum Type Fiat Normal Ready INTRODUCTION SECTION A PAGE 18 A 7e Xfer Cvyr Transfer Conveyor Setup GBR Systems Folder Setup GBR Systems Xfer Cvyr Ready A 7d Folder Folder Enable Leave selected not functional at this time Ready 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 INTRODUCTION 071 28558 401 SECTION A PAGE 19 GBR Systems Infeed Setup Infeed Type or v Creeper Bulk Cutter 1 Printer Cutter RA v Cutter ST Feed Max Low Count 0 Printer Cutter RA Cutter ST Full Delay Time 800 Off Delay Time 45000 l If42 jam Time 800 Finish Delay Time 5000 1 1 Inf
100. eed Response Time 120000 Creeper ON Time 1000 Process Status Ready A 7f Infeed Setup Infeed Type Off Creeper Select when using the standard 2000 sheet creeper conveyor Bulk 470 type bulk loader with on off control by software monitoring the paper demand switch Cutter 1 Guillotine type cutter feeder Printer Flat sheet printer feeder Cutter RA A guillotine cutter set in right angle configuration feeding onto a right angle or turning device then feeding into the accumulator Cutter ST A cutter feeding directly into the accumulator 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 Feed Max Low Pertains to a friction or suction feeder wherein a setting can be made to set the number of sheets left in the feeder It will set the number and prevent the feeder from running out completely preventing the operator from having to reload from scratch Printer Cutter RA Cutter ST This setup section allows the operator to set a time delay for each of the following feeding devices The function of the delay is the same for each device it enables the document some amount of time to feed into the accumulator or it will declare an error Full Delay Enter time of delay desired IF42 Jam Enter time of delay desired Finish Delay Enter time of delay desired Infeed Response Enter time of delay desired Creeper On Enter time of delay desired INTRODUCTION SECTION A PAGE 20 A 7g
101. eens GBR OMR Reader Setup Read Zone Diagrams Postal Meter Setup Presets Software Updates Via Email ECTIONB PREVENTATIVE MAINTENANCE SECTION C ELECTRONICS SECTION D PROBLEM ANALYSIS Test Screens General Solutions to Problems Error Codes Possible Causes of Errors Repair Checkout Procedures SECTION E ADJUSTMENT amp REPAIR INFORMATION Feeder Accumulator Folder Section Transfer Conveyor SECTION F MACHINE SCHEMATICS SECTION G A INTERFACE TO OPTIONAL EQUIPMENT Connecting to an Inserter 438A SERVICE MANUAL ISSUE 2008 05 071 28558 401 A COVER PAGE 3 438A SERVICE MANUAL ISSUE 2008 05 COVER 071 28558 401 A PAGE 4 2 HEADERS FOOTERS The information listed along the left edge refers to the machine the manual type and the part number and revision level for that manual The particular issue listed in the center is an internal tracking device The top line of information along the right side states the title of the particular section The bottom line lists the section and the page number within that section 3 LIST OF CHANGES IN THIS REVISION ECN 9606 Issue Date 3 5 2008 Revision This is a first release for the 438A V4 Service Manual Software supported by this revision XXX XXXXX XXX Changes incorporated in this manual Section Change New Release 4 SECTION ISSUE DATES Sect A XXXX 08 Sect B XXXX 08 Sect XXXX 08 Sect D XXXX 08 Sect XXXX 08 Sect F XXXX 08 Sect G XXXX 08 438
102. elected GBR Systems Revision 31264 008 3 Aug 31 2007 16 01 14 i Packages Sheet Sheets Pack Rate Demand Rate 10 03 07 See Section A 7 for Setup Screens 0 0 0 0 0 11 42 45 See Section D Problem Analysis for Test screens EOG Group Page Total Diverts Batch e The current screen 0 9 9 0 raa ote Test Press to enter diagnostic screens for more information refer Insert Marks Control Marks Diagnostic to Section D 000000000000 000000000000 e Setup Press to enter setup screens for more information refer to Section A 7 Monitor Events 6 EN 15 01 01 NV IniFile OK Release Brakes Releases Applies Accumulator and Feed Brakes n Wa AAS to allow jam clearing 15 01 01 CPU Type Version DXS V01 15 01 01 NV Disk Type RamDisk Information Displayed 15 01 01 Feeder Feed Sensor Interrupt Disable ici i S 15 01 05 Barcode Setup Started e Revision Software and Build Date top line 150105 Lla Ra Panas e Packages Total package counter Reset in System Setup Also 15 01 05 Lineread Setup Done 15 01 05 LineReader Software Version 08103 003 resets during bootup Sheet Displays the of sheets in the accumulator Total Sheets Displays the number of sheets fed from the time the Status Poweron o0 System was powered up Resets on machine power down e Pack Rate Used to monitor throughput of the 438 Calculated at every pack dumped from accumulator not averaged e Demand Rate Displ
103. er 1 e Select Postal Meter Divert Enable ON to operate from a read mark ONLY e Select Postal Meter Divert Enable OFF to operate from Weights ONLY Inserter Setup Postal Meter By Weight Enable Check ON to enable Postal Meters Inserter Setup 2 Postal Meter Divert Postal Meter 1 e Enter Meter ON AT in degrees 0 to 350 After 90 degrees e Enter Meter OFF AT in degrees 0 to 350 Before 90 degrees e Enter Meter Position STA e 1 12 after envelope insert station e 0 to disable this meter e Enter Point Option PT e 9 Postal Meter Divert DEFAULT e 10 Postal Meter Divert Inverted Signal Inserter Setup 3 Postal Meter 2 e Enter Meter ON in degrees 0 to 350 After 90 degrees e Enter Meter OFF AT in degrees 0 to 350 Before 90 degrees e Enter Meter Position STA e 1 12 after envelope insert station e 0 to disable this meter e Enter Meter Output Point Option PT e 1 Station 7 Select DEFAULT e 2 Station 8 Select e 3 E Stop e 4 Station 1 Error e 5 Station 7 Select Inverted Signal e 6 Station 8 Select Inverted Signal e 7 E Stop Inverted Signal 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 e 8 Station 1 Error Inverted Signal e 9 Postal Meter Divert DO NOT USE e 10 Inverted Postal Meter Divert DO NOT USE e 11 Moistener e 12 Moistener Inverted Postal Meter 3
104. es A stack sensor marked with an S detects paper arriving in the accumulator and is positioned just before the downstream edge of the ramps The accumulator sensor marked with an A indicates presence or absence of a package in the accumulator and is positioned just downstream from the back edge of the ramps It also monitors for successful package discharge when the dump clutch has been activated E 2b Accumulator Clutch and Brake Adjustments The accumulator clutch is designed with a preset gap no adjustments are possible or necessary There should be a slight amount of rotational free play in the clutch body to prevent binding The accumulator brake does require a gap setting of 005 This setting is critical too tight and the drag on the clutch will cause premature wearing of the clutch and the brake Too wide of a gap and the stacking rollers won t stop the documents correctly in the accumulator 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 XXXXX 400 ACCUMULATOR CLUTCH amp BRAKE SETTING ADJUSTMENTS amp REPAIR INFORMATION SECTION E PAGE 9 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 XXXXX 400 E 2c Accumulator Dump Roller Replacement To replace the dump rollers it is first necessary to disconnect the accumulator from the folder 1 Disconnect all electrical connectors to the feeder 2 Remove the left feeder cover 3 Loosen the t
105. etected at the Accumulator presence sensor to start the next pack feed Higher is safer lower is faster but assumes pack leaves Accumulator Advance Feed OFF Time msec from pack movement at the detected at the Accumulator presence sensor to start the next pack feed 03 150 Bar Read Time Range 0 gt 9995 Inc 5 Time msec waiting for reader response 04 250 Folder Exit Time Range 0 gt 9995 Inc 5 Time msec allowed for pack to reach the folder exit sensor Straight Conveyor Only 05 150 Line Read Time Range 0 gt 9995 Inc 5 Time msec waiting for reader response 06 10 Xcvy Dump To Acc Dump Time Range 0 gt 9995 Inc 5 Time msec from Xcvy is going to move until next Accum dump is started 438 V4 OPERATOR amp SERVICE MANUAL 071 28558 401 Number Value Description 07 100 Xcvy Clutch On Time Range 0 gt 9995 Inc 5 Time msec Xcvy clutch is on adjusted for number of stations Adjust up down to place the last pack at the Xcvy exit 08 300 Xcvy Into Station 1 Time Range 0 gt 9995 Inc 5 09 50 Xcvy Outof Station 1 Time Range 0 gt 9995 Inc 5 10 400 Folder Start To Conveyor Time Range 0 gt 9995 Inc 5 Should be greater than Eng Value 04 Folder Exit Time when Exit Type is Conveyor and not in test 11 0 Test Console Switch Range 0 gt 1 Inc 1 0 turns off d
106. eter Feature Selection Setup 4 Inserter Encoder amp Timing Setup Inserter Protocol Type Select either Inserter or Postar The following I O points have dual usage depending on Protocol selected and interface PCB used 002d 08138 or 002d 07599 438 V4 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 l O Rack 1 RIGHT INSERTER U S Application 1 04 Separation Sol 1 05 Separation Sol 1 1 06 Separation Sol 8 1 07 Shingle Conv Motor 1 08 Separation Sol 2 1 09 Separation Sol 3 1 10 Separation Sol 4 1 11 Separation Sol 5 1 12 Separation Sol 6 1 13 Separation Sol Env 1 14 Ink Marker Sol 1 15 Env Flap Sns Dis 1 16 Emergency Stop 1 17 Ins Station 1 Error 1 19 Postal Meter Divert 1 22 Cutter Jam Sensor POSTAR Typical European Application Postar Data Bit 1 Postar Data Bit 2 Postar Data Bit 3 Postar Kicker Postar Data Bit 4 Postar Data Bit 5 Postar Data Bit 6 Postar Data Bit 7 Postar Data Bit 8 Postar Data Bit 9 Postar Data Bit 10 Postar Data Bit 11 Postar Data Bit 12 Postar Error Bit Postar Strobe Bit Postar Kick Sensor Selection Direction is used for setting the protocol for insert station numbering Postal Meter by Weight Enable To select the Postal Meter Stamping feature Degrees The Inserter Encoder updates this window as the inserter runs Home The home position of the inserter be seen shifting from a zero
107. eter Setup 4 Pause Degree Rate x1000 Pause Switch Degree 0 1 2 3 4 5 E 7 8 8 10 OnDeg 330 330 310 290 270 250 230 210 190 170 150 t l Pause Calib OFF In Track Check OnAt 489 Inserter Monitor Ready Pause Degree 0 to 999 On Deg 330 1000 to 1999 On Deg 330 2000 to 2999 On Deg310 3000 to 3999 Deg290 4000 to 4999 Deg270 5000 to 5999 On Deg 250 6000 to 6999 Deg 230 7000 to 7999 Deg210 8000 to 8999 Deg 190 9000 9999 On Deg 170 0 1 2 3 4 5 6 7 8 9 10 10000 On Deg 150 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 Pause Type Switch or Degree In Track Check On At 180 Refer to Section H 4 for an example of a Typical Postal Metering Setup Preset INTRODUCTION SECTION A PAGE 26 A 7j Engineering Values Password Protected GBR Systems Setup sen Foe rai Line M Enter Value Reed Enter 4 Digit Password HE TA ia Value For settings refer to Section A 8 for the default Engineering Values List Reset to Default Press this button to reset only the current Engineering Value displayed back to its default value This value is changed on the display only Pressing the OK button saves the default value Cancel exits and returns the Engineering Value to the prior value 438 V4 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 A 7k ExitCom
108. ets in same track 49 0 Accum pack Bad Set Divert By Read Bit Range 0 gt 1 Inc 1 Default 0 0 Default Normal operation 1 Sets Divert by Read bit if the pack is not valid 50 0 ReadLess Read Mode Range 0 gt 1 Inc 1 Default 0 0 Default Normal operation 1 Special error recovery routine when using Demand Feed type Read first in barcode for FPF 35 51 1 First pack Dumped Error Enable Range 0 gt 1 Inc 1 Default 1 1 Default Normal operation 0 Disables setting bad pack on first pack processed after startup or purge 52 1 Feed amp Accum pack Error Enable Range 0 gt 1 Inc 1 Default 1 1 Default Normal operation 0 Disable setting bad pack on Feeder or Accum Errors 438 V4 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 INTRODUCTION SECTION A PAGE 31 A 9 LINE CODE READ SYSTEMS OPTION A 9a Introduction The Line Code Recognition System is capable of decoding line code marks that are on 1 10 1 8 or 1 6 spacing There can be as many as 25 mark locations in a bank with a possibility of two banks per each channel of Line Code marks A Single Line Code Recognition card supports input information from two probes The second probe is a optional feature The system is limited to having only one of the two probes active at any one time If more than one channel of Line Code marks is required to be recognized on a single documen
109. eyor relative to the feeder is an important adjustment To adjust a Place a sheet of paper in the feed area up to but not under the singulator b Loosen the four set screws of the creeper guide rails Once this is accomplished the conveyor will move freely in and out Do not pull it all the way out of the clamps it will fall C Bring the hopper table 1 2 away from the back edge of the sheet of paper d Tighten the four set screws to clamp the table in this position Whenever document length is changed this process must be performed to ensure the proper transfer of paper from the hopper table to the feeder area ADJUSTMENTS amp REPAIR INFORMATION SECTION E PAGE 3 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ADJUSTMENTS amp REPAIR INFORMATION 071 XXXXX 400 SECTION E PAGE 4 Paper Level Detector The demand switch 3 monitors the paper through a metal Setting Main Feed Belt Tension wand 1 On the top of the wand is a spring loaded hex head The feed belt provides the primary force separating a sheet adjustment bolt which when turned raises and lowers the from the bottom of the shingled stack The setup procedure for wand this belt is described below The feed belt tension adjustment Raise the wand to allow more paper to be fed into the knob is factory set limited to approximately 3 4 turn This is feeder adequate operator adjustment for typical paper weight Lower the wand to reduce the amount of paper v
110. f characters Start Bit 0 to 30 Starting bit position within character Length Bit 0 to 30 Number of bits Demand Feed Code Start 0 to 30 Start character Length 0 to 20 Number of characters Used with Normal A or Reverse A multiple character numeric values Start Bit 0 to 20 Starting bit position within character Ink Mark Code Start 0 to 30 Start character Length 0 to 20 Number of characters Used with Normal A or Reverse A multiple character numeric values Start Bit 0 to 20 Starting bit position within character PmDivert Code Start 0 to 30 Start character Length 0 to 20 Number of characters Used with Normal A or Reverse A multiple character numeric values Start Bit 0 to 20 Starting bit position within character A 10g Adjusting the Paper Guide Belts In order for your laser scanner to read the bar code there can be nothing blocking its path The Paper Guide Belts are custom adjustable for your specific code location Place these guide belts to provide as much support evenly across the paper path as possible without interfering with the lasers view INTRODUCTION SECTION A PAGE 47 A 10h Bar Read Setup 3 GBR Systems Bar Read Setup 3 Total Page Code Stat 5 Length 1 StartBit O LengthBit 0 1 1 l Sq Stop Code Start 0 StariBit O Subset Code Stat 0 StartBit O l 1 1 l j L t Unseal Code Statt 0 StatBit 0 Stitch Code StartBit O StartBit 0 l I l 1 1 l No St
111. g the adjustment is described below Note This adjustment is normally done only when a new singulating roller is installed It is not necessary to adjust it on a regular basis 1 Cut two strips of paper from the same document approximately 1 2 x 8 2 Put them between the two lower rollers and the large Singulating Roller 3 Adjust singulating roller until light tension is felt on the paper between the rollers 4 Check that the tension on both strips of paper is the same If it is not the same then adjust the geometry of the singulating roller 5 Loosen the 10 32 x 5 8 socket head cap screws 4 on the side rail or the back of the singulator plate Adjust either to best advantage 6 Carefully position the singulator using the small amount of play available to raise the side of the singulator that has the most tension 7 Tighten the 10 32 x 5 8 socket head cap screws loosened in step 5 8 Retest the tension of the two strips of paper by returning to step 3 ISSUE 2008 05 ADJUSTMENTS amp REPAIR INFORMATION SECTION E PAGE 6 Rotating Singulating Roller The singulating roller is the place where the highest frictional forces are created These frictional forces wear down the singulating roller This requires that the singulating roller be rotated approximately every 250 000 sheets fed depending on paper type and operator s adjustment of the singulator 1 Raise the singulating roller above the feed r
112. ge of previous page not sensed e This error can be caused by electronic noise generated by the 438 or a connected machine INITIAL ACTION e Ground the 438 and the connected machine i e inserter together e Plug the Open Feed Sensor into the Transfer Conveyor Exit Sensor Plug if using this option e f 438 is not in a read mode go to Setup Feeder gt gt Pulse Feed and make sure None is not selected 12822 LONG PAGE FED Purpose page being fed stays under the feed sensor too long or the Page Length setup is incorrect EVENT Feed Clutch ON page lead edge and trail edge through Feed Sensor EVENT CHECK JamTimer CHECK VALUE 150 msec Sheet Length 150 Speed ADJUST VALUE Cause Time exceeded 12823 12825 12826 12827 EXTRA PAGE WAS FED Purpose EVENT Page lead edge at Feed Sensor EVENT CHECK Feed Sensor CHECK VALUE ADJUST VALUE Cause Page lead edge at Feed Sensor Feed not processing FEED TO ACCUMULATOR JAM TIME Purpose EVENT Feed Clutch ON page lead edge and lead edge through Accum Sensor EVENT CHECK FeedToAccumTimer CHECK VALUE 170 msec CHECK VALUE 160 Speed ADJUST VALUE Enginerring Value 24 Cause Time exceeded SPEED LOW Purpose EVENT Feed Encoder Sensor EVENT CHECK Calculate and Average speed CHECK VALUE 25 inches per second ADJUST VALUE ANALYSIS Speed less than value FEED SENSOR COVERED Purpose EVENT Feed Sensor ON EVENT CHECK
113. ghten simultaneously 27 Reset position of round belt pulley and rollers and tighten Reinstall top guide E 3 FOLDER E 3a Description Refer to the Fold Capacity Chart at the end of this manual Fed by the accumulator section the folder is capable of placing 1 to 8 sheets in a C or Z configuration and up to12 sheets in a V fold maximum of 24 panels in any configuration Adjustable buckle plates set the distance of the fold from the edge of the paper Fold rollers nip the paper as it is buckling creating the fold A 220VAC motor drives all folder shafts and rollers The folder speed encoder located on the infeed roller shaft provides a folder speed signal Depending on the particular configuration documents exit the folder in one of three ways 1 Shingling conveyor stacker The stacker allows easy continuous removal of document s while avoiding any loss of sequence 2 Buffered transfer conveyor where nest folded documents are placed in an open station inserter track section 3 Transfer conveyor where the nest folded documents are presented to the gripper arm 438 OPERATOR amp SERVICE MANUAL 071 XXXXX 400 ISSUE 2008 05 E 3b Fold Principle The folder works on the buckle fold principle using a fold plate and fold rollers Fold rollers 1 and 2 drive the sheet into the 1 fold plate until it comes up against the adjustable stop The trailing edge of the sheet continues to be advanced by the roller and the sheet
114. hey interlock with the Feeder rails then lock to shafts running across the machine Both sets of rails should be adjusted and aligned together A one inch wide timing belt main feed belt drives the bottom sheet of paper under the singulator roller Two urethane belts are located to either side of the main feed belt and assist the main feed belt smoothing variations in frictional drive A paper demand wand and switch mechanism senses the level of the paper going into the feeder area It s job is to regulate the amount of paper in the feeder area providing the most productive feeding A two inch stationary roller singulator roller rests above the feed belt in the center of the feeder and allows only the bottom sheet of paper to be fed while holding back all others ADJUSTMENTS amp REPAIR INFORMATION SECTION E PAGE 2 A series of sensors monitors the flow of paper through the 438 Feeder System These are known as retro reflective sensors and require no adjustment Each sensor is aimed at a reflective tape placed on the other side of a gap through which the paper travels The sensor looks constantly at its reflection from the tape and reports when the reflection disappears paper presence The feed sensor monitors correct feeding and non feed of paper while other similar sensors located in the accumulator section detect stacking and releasing of paper Read sensing is accomplished by a Line Code Reader on either or both the left
115. hutdown Cir Last Stop Last Cir 1st Stop ist None Item Verify First Pg Last Pg Off Ink Mark PM Divert Unseal Subset Mk Random Mk No Stop Max Errors 0 Subset By Count 0 Random Count 0 I l 1 l l l Process Status Ready Demand Feed Normal The machine will demand feed on the absence of an End Of Group mark This means the only page in a set that has the mark is the last one Reverse The machine will demand feed on the presence of the End Of Group mark This means the all pages in the set will have the mark except the last one Yes No Used where all pages have a mark Each page will have an End of Group or a NOT End Of Group mark EOG mark missing The machine will demand feed on EOG but all other documents in the set should have the NOT EOG mark First Page When only the first page will have an EOG mark Last Only When this option is selected the system looks for the end of group mark demand feed on the last page of a set to be fed into the accumulator This option is intended for use with page sequencing configured as page down INTRODUCTION SECTION A PAGE 33 GROUP SEQUENCE UP Choose if the group is counted UPward 1 2 3 4 Sets must be in order DOWN Choose if the group is counted DOWNward 4 3 2 1 Sets must be in order MATCHING will match marks within a set All marks in the set must be the same Sets may be in random order SAME ID The group sequence is checke
116. iagnostics only used in debug mode 12 1 Language Select Range 1 2 Inc 1 1 English 2 English 13 0 Xcvy Package InOut Counter Range 0 gt 9995 Inc 5 Max Number of packages expected in Xcvy 0 disables this check 14 150 Acc Dump Clutch On Time Range 0 9995 Inc 5 Constant value Accumulator clutch is on adjusted for speed Adjust up so pack fully exits Adjust down if next pack is partially pulled under rollers 15 5 TouchScreen X Correction Range 60 gt 60 Inc 1 Constant value for touch sensing Adjust up to move sense right Adjust down to move sense left 16 10 TouchScreen Y Correction Range 60 gt 60 Inc 1 Constant value for touch sensing Adjust down to move sense up Adjust up to move sense down 17 20000 Paper Demand Time Range 0 gt 60000 Inc 500 Time msec waiting for paper stack switch in feeder to be satisfied by infeed ISSUE 2008 05 INTRODUCTION SECTION A PAGE 28 Number Value Description Number Value Description 18 3 Max Xcvy Stations Range 2 6 Inc 1 26 1 Comm Hardware Type Range 0 gt 1 Inc 1 Max Number of package positions in Xcvy 2 6 0 Ziatech 1 WinSystems 19 0 Test ExitComm Test List Switch Range 0 gt 255 27 4444 Eng Values Password Range 0 gt 9999 Inc 1 Inc 1 4444 Default 9561 is backup 0 No extra
117. ial occurs when the last pack is accumulated the machine stops feeding purges the accumulator and transfer conveyor to the inserter then powers down Sheet Length Double Arrow Up button increments in tenths of an inch to standard sheet sizes 7 8 5 11 14 A4 and A5 Single Arrow buttons adjust sheet length in tenths of an inch 438 V4 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 Package Size Max Pages in Accumulator 1 to 12 For Read 1 greater than max expected 5 for the LineCode test set Or number of fixed pages with no read Reader Type Line Bar None Off Exit Conveyor Type Inserter Online By demand See Inserter Setup 1 for Open Station or Gripper Arm setup Inserter Offline Selecting this allows the inserter to run independent of the 438 without physically detaching Hopper Fill Select HOPPER FILL when the inserter will be taking the folded documents from a hopper With or without demand See Eng Value 20 With no Inserter Conveyor with or without demand See Eng Value 20 selects whether or not to ignore the demand signal with no Transfer Conveyor Xfer Cvyr Exit at Folder with Folder Exit Sensor for straight shingling style of stacking conveyor Batch Processing Sheet Select job size by entering the number of sheets to run When selected the Batch Off button changes to Set Sheets When Sheet is selected and a batch size entered the machine
118. ination Fold Plate MM 438 on the first fold plate It is possible to change the parallelism of the stop by turning the knurled knob 1 Loosen the knurled knob by means of a 4 mm allen key 2 The angle of the stop is changed by turning the two knurled knobs The stop is parallel to the fold rollers when the two half round marks 3 face each other 438 OPERATOR amp SERVICE MANUAL 071 XXXXX 400 ISSUE 2008 05 Shadow Fold MM 438 The lower lip can be adjusted by setting knob 5 Basic position 0 is flush with the top of the knob Lower lip advanced Small buckle space setting knob Lower lip set back Large buckle space setting oo knob Thin paper grades Advance lower lip Heavy paper grades Set back lower lip Accordion Fold It is possible that heavy paper grades get stuck and form a so called accordion fold In such a case the fold plates must be set back A Loosen the allen screws 6 both sides of the fold plate Set back the fold plate using the scale 7 Tighten the allen screws Change the fold stop plate by the same amount ADJUSTMENTS amp REPAIR INFORMATION SECTION E PAGE 25 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ADJUSTMENTS amp REPAIR INFORMATION 071 XXXXX 400 SECTION E PAGE 26 Creasing An additional scale 2 indicates adjustments of 0 5 mm When special types of paper are folded deviat
119. ineering Values 08 Xcvy Into Station 1 Time This applies to a straight conveyor as well with the exceptions that the exit sensor on the folder is used instead of the transfer conveyor and the time allowed is set in Eng Values 04 Folder Exit Time A counter feature also keeps track of the number of packs in the folder When a pack leaves the accumulator it is incremented by 1 When a pack reaches the input sensor of the transfer conveyor or the exit sensor of the folder when a straight conveyor is used the count is decremented by 1 If this count reaches 3 a folder jam is declared Initial Action Check sensors Check engineering values refer to section H Engineering Values E 4 TRANSFER CONVEYOR E 4a Description The transfer conveyor is an articulated belt system which presents the nest folded document s to the Inserter gripper arm E 4b Timing Demand switch on off timing is critical The setup of this timing permits the 438 to achieve optimal handoff to the Inserter The demand switch should be made contacts closed when the gripper arm is approximately perpendicular to the deck of the Inserter This point occurs twice each 360 degree cycle of the inserter With the gripper arm fully into the insert station the inserter is said to be at zero or home position During a single cycle of the inserter the gripper arm starting in this position will move toward the track When the arm becomes perpendicular to the d
120. ions from the nominal values may become necessary One turn of the setting knob changes the roller gap by 0 5mm Individual corrections can be made by means of the numbered setting knobs at each roller The fold rollers and delivery shafts with the matching setting knobs are arranged according to the following scheme Roller 1 is the infeed roller Roller 2 makes the 1 fold Roller 3 makes the 2 fold Roller 4 makes the 3 fold Roller 5 makes the 4 fold Roller 6 is the ejector roller setting knobs are equipped with scales 1 With their help settings with a precision of 0 1 mm are possible To increase the roller gap turn the setting knob counter clockwise E When the roller gap is changed by more 20 10 than 0 5mm the values on both scales must be added Example 0 5 2 16 1 0 66 mm P BN N s 4 Standard 438 Folder Knob Setup 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ADJUSTMENTS amp REPAIR INFORMATION 071 XXXXX 400 SECTION E PAGE 27 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ADJUSTMENTS amp REPAIR INFORMATION 071 XXXXX 400 SECTION E PAGE 28 FOLDER JAM Analysis When a pack exits the accumulator but isn t detected by the input sensor in the transfer conveyor station one an error is generated and the machine stops This prevents damage to the folder The amount of time allowed is set in Eng
121. is broken or E stop condition E STOP Press to shut down all motors on the 438 in emergencies E Stop must be twisted to bring back to original position Lifting any cover will also shut down all motors on the 438 INTRODUCTION SECTION A PAGE 14 A 7 SYSTEM SETUP SCREEN GBR Systems Setup Press Setup while in the Run screen This screen provides access to all 438 setup screens Press Run to return to the Run screen Note Normal factory settings are in bold font 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 INTRODUCTION SECTION A PAGE 15 A 7a Setup GBR Systems System Setup Package Count Total Sheets Batch Process Off Reset Reset Reset Sheet Length Tenths 110 11 in n Package Size Sheets 4 Total Set Size sheets l t Reader Type Line Bar v None Exit Conveyor Type Inserter Online Conveyor inserter Offline Hopper Fill Batch Processing Sheet Package Off Ready Package Count Reset Resets total package count Packages found in Run screen This value will also reset automatically on power down of machine Total Sheets Reset Batch Process Reset On Off status is also displayed Resets the Total Sheets or Total Packs depending on which option was selected found in the Run screen This value will also reset automatically after the sequential stop determined by the batch size entered A sequent
122. l MR AI BIG ELA uy Sequence is maintained PM Divert At 9 SubsetAt O RandomAt Q SeqStopAt UnsealAt 0 f l I l J j 1 1 1 Ready increment from package to package when sequentially counting sheets upward This number sequentially counts from 0 to 15 Page Seq Mark Purpose Identify each individual page within a package The sequential incrementing of the number ensures the documents are assembled in the proper order Usage It is interpreted as a binary number This number sequentially counts from one to as high as seven Inserts Mark The length will coincide with the number of stations on the inserter e g six stations a length of six lines with each line representing a station If the code shows a mark at one of the positions the corresponding station will feed an insert Gate Mark Location First OMR mark within a bank always present 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 INTRODUCTION 071 28558 401 SECTION A PAGE 39 Purpose Indicates the start of an OMR code Usage synchronizes the OMR system to interpret the remaining OMR marks in the code Total Marks is the number of marks in the current line code block from gate mark to the end EOG At Purpose Controls the size of dynamic packages by indicating the end of a group Usage A solid bar is placed in this location on the page with the largest page ID number All other pages within a group should have no mark in this area Not
123. l Page demand feed option Total Dn Z A None Min 0 to 1 Max 0 to 999 Count Skip Ink Mark Mark to drive an ink zip marking mechanism downstream Meter Divert Mark to drive a divert mechanism downstream Subset Mark Unseal Mark Stitch Mark INTRODUCTION SECTION A PAGE 45 Seq Shutdown Clr last Stop Last Cir 1st Stop 1 None When a package with this bit set is accumulated the machine stops feeding purges the accumulator and transfer conveyor to the inserter then powers down Bit Direction Normal Count bits 5 to 1 left to right bit position 4 to 0 follow standard bit position of character Reverse Count bits 1 to 5 left to right bit position 4 to 0 B amp H Normal A For multiple character numeric values For 5 numeric characters converted to a number bit positions 16 to 1 1 2 4 8 16 32 64 128 256 512 1024 2048 4096 8192 16384 32768 Reverse A For multiple character numeric values For 5 numeric characters converted to a number bit positions 1 to 16 1 2 4 8 16 32 64 128 256 512 1024 2048 4096 8192 16384 32768 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 Bit Number Establishes the maximum number of bits in one character This is determined by the type of code being used Select from 1 through 8 1 5 3 of 9 Bar Code 6 8 not used at this time INTRODUCTION SECTION A PAGE 46 A 10f Bar Read Setup 2 GBR Systems
124. l of 775 Inserter functions station Select Envelope Disable Envelope Flap Detect Disable InkMark Divert Postal Meters 438 V4 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 AC DC 420T 438 control of non 775 Inserter functions station Select Envelope Disable Envelope Flap Detect Disable InkMark Divert Postal Meters Demand Type Switch Select when demand signal is provided by a magnetic switch Degree Select when demand signal is provided by an encoder Serial Select when demand signal is provided through an RS232 interface by a semi intelligent inserter Bad Pack Stop Enable This box is defaulted on or checked The machine will stop on a bad pack and energize the bad pack indicator light on the inserter If unchecked or off the machine will not stop on a bad pack Subset Method of inserting more than one accumulated packs into one envelope on the inserter None subset pause not used Pause inserter will not advance until the transfer conveyor feeds second pack into open feed station Remove inserter will not advance and permits the operator to remove the packs deposited in the open feed station on the inserter Station Setup Note Insert Station positions are referenced from the station at which the documents are inserted into the envelope Insert Sta 0 Insert Station 1 would be the station downstream from Insert Station 0 Insert Station 1 is the Insert Station upstream from In
125. ly comes from the inserter but may come from the 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 GBR438 If there are two power supplies care must be taken not to cross connect them e General installations use 1 or 2 postal meters and we normally use GBR438 postal meter 2 and 3 leaving postal meter 1 Postal Meter Divert to be used as postal meter or a oversize divert station e The actual order of the meters after the end of the Inserter should be Hi to Lo weight PM1 PM2 e The Postal Meters must be positioned after the last index position of the Inserter and all meters must be stacked as close as possible together Operation e The GBR438 tracks the pack only to the last index position of the inserter The GBR438 actually disables the meters which are not to be used leaving the one meter enabled to meter the pack e The GBR438 uses the inserter degree encoder to provide fine timing by degrees of the disable enable signal to the Postal Meters e The ON degree must come AFTER the Logical Shift 90 Deg of the pack data in the GBR438 inserter software module The OFF At degree must come BEFORE the next Logical Shift 80 Deg of the pack data in the GBR438 inserter software module This cycle should occur between 100 and 80 degrees e Only one pack can traverse the meters at any time INTRODUCTION SECTION A PAGE 51 Setups Lineread Barread Setup Postal Meter Divert Enable Postal Met
126. m GBR Systems Exit Comm Setup Exit Comm Pinnacle 2 Exit Comm Test 09 18 08 Powered Up 13 43 04 Xmit 000302 13 43 32 Xmit 000304 13 44 02 Xmit 000304 13 44 05 Xmit 000304 13 44 08 Xmit 000304 Ready Type 0 No Comm 1 RR Donnelly 1 2 RR Donnelly 2 3 Pinnacle 1 4 Pinnacle 2 5 General 6 Tampa 1 7 Zaandam 1 8 Friedberg 1 Start Button Xmits test data in type selected Displays response terminated by a CR LF Press again to stop Event List INTRODUCTION SECTION A PAGE 27 A 8 Number ENGINEERING VALUES These values are to be used as a starting point These values may vary depending on type and weight of paper being processed environmental conditions and system tolerances in order to obtain optimal performance The password to enter this screen is factory set to 4444 This password may be changed at Engineering Value 27 Eng Software Version 31264 008y3 xxxxx xxx Number Value Description 01 20 Acc Feed Settle Time Range 0 gt 9995 Inc 5 Time msec after trail edge of last page passes Accumulator stack sensor into Accumulator until Accumulator clutch is fired 02 40 Acc Dump Done Time Range 0 gt 9995 Inc 5 Advance Feed ON Time msec from Accumulator is going to dump until next feed is started A short value advance feeds before the pack moves from the Accumulator A longer time allows pack movement d
127. n by pressing 1 or 4 Note If your job is not listed go the next section Setup 1 to program it in Refer to the Appendix in this manual for setup parameters for various jobs If your job is not listed call the factory Start This will turn the laser on continuously to hand test the lasers positioning The screen will read BAR READ and an audible beep will sound when the laser reads the code The results of the read will be shown on the screen Reset Job Defaults Sets the bar job selected to its defaults erasing any modifications that may have been done in the setups Press OK to set the job INTRODUCTION SECTION A PAGE 44 A 10e Bar Read Setup 1 GBR Systems Bar Read Setup 1 Demand Feed Normal Reverse Total Pg Read First BOG Mark Group Chg CustID Chg Group Seq Up Down Matching Same D v None Group Seq Min 1 Max 4 ux 1 j Keypad Page Seq Page Up Page Down Roll Up Roll Down Total UP Total v None Page Seq Min 1 CountSkip 1 t 1 1 Ink Mark Meter Divert Subset Mark UnSeal Mark Stitch Mark Seq Shutdown Cir Last Stop Last Cir 1st Stopist None Bit Direction v Normal Reverse Normal A EY Bit Number 1 2 3 4 5 6 Ready Demand Feed Normal Mark is on the last page fed Last page is 1 all others in the pack are 0 Reverse If checked will handle an inverted Demand Feed sequence Last page is 0 all others in the pack are 1 T
128. nd the associated black wire is 12vcom The board is labeled below the connector Just to the right and on the lower right of the previous page are photos of the Read Interface Panel It is used internal of the read housing to bring the connections out the front panel of the housing and connects to the read board inside SECTION C PAGE 14 Read Interface Panel Component Side 042 30445 500 12 03 2008 10 30 C 10 INK MARKER CONTROL BOARD Ink Mark Control Bd 042 25974 500 gt YAW EM The above is a picture of an Ink Marker Control Board which permits an operator to control zip code sequencing on an inserter that supports Ink Marking When the read code on a package which has been read by the GBR Feeder is delivered to the inserter information is passed to the inserter This information can include a line or mark which will indicate if the zip sequence has changed whether or not the ink marking device should be activated when the envelope is passed from the inserter toward the stacking device 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 15 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 16 C 11 CREEPER CONVEYOR MOTOR CONTROLLER T kiy xui tailed The V4 Friction Feeder uses a 90vdc motor shown here in two pictures controller to adjust and maintain speeds of the motor by a set constant voltage output
129. o the two rollers on the lower shaft is critical This spacing creates the singulating gateway The setup process is as follows Place one sheet of paper under the singulator 2 Lower the singulating roller so the sheet can not pass under the roller Use chrome knurled knob 3 Slowly raise the singulating roller by rotating the chrome knob clockwise 4 Attempt to pull the document out while slowly raising the singulating roller 5 When the document starts to move as you firmly pull it under the singulating roller proper singulation adjustment is achieved 6 Load the feeder area with paper and make a test run 7 If more than one sheet is fed lower the singulator two knob clicks If after adjusting as many as five knob clicks proper feeding is not obtained then all of the setup procedures for the singulator should be reviewed 438 OPERATOR amp SERVICE MANUAL 071 XXXXX 400 ISSUE 2008 05 NOTE Proper singulator adjustment depends on paper variables such as stock finish and environmental factors Specific adjustment on every job will be different Adjust the singulator roller as paper is feeding to get best setting ADJUSTMENTS amp REPAIR INFORMATION SECTION E PAGE 5 438 OPERATOR amp SERVICE MANUAL 071 XXXXX 400 Set Singulating Roller Parallel to Lower Rollers The gap between by the singulating roller and the two lower rollers must be equal for both of the rollers The procedure for testing and makin
130. oller 1 is the infeed roller Roller 2 makes the 1 fold Roller 3 makes the 2 fold Roller 4 makes the fold Roller 5 makes the 4 fold Roller 6 is the ejector roller 438 OPERATOR amp SERVICE MANUAL 071 XXXXX 400 ISSUE 2008 05 The basic principle of buckle plate folding has to be considered when choosing the correct setting of the fold rollers There are two different types of fold Folds with always symmetrical panels Folds with partly asymmetrical panels Folds with always symmetrical panels If the panels of a folded sheet always have the same length when passing through the fold rollers the gap to be set for the respective fold roller depends on the number of paper layers which have left the preceding fold plate Folds with partly asymmetrical panels If the panels of a folded sheet are of unequal length when passing through the fold rollers accordian fold letter fold in fold plates 1 and 2 the gap to be set is governed by the number of paper layers contained on the longer panel ADJUSTMENTS amp REPAIR INFORMATION SECTION E PAGE 23 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ADJUSTMENTS amp REPAIR INFORMATION 071 XXXXX 400 SECTION E PAGE 24 E 3j Fine Adjustments and Corrections Fold Length Fold variations may occur if the fold plate stops are not set accurately of if the folding speed is changed The fold is off across the whole width of the sheets as opposed to a skewed fold
131. ollers and feed belt until there is a gap 2 On the left hand side of the singulating roller use a 5 64 allen wrench to loosen the set screw which keeps the singulating roller from rotating 3 Rotate the singulating roller to expose a new wear surface rotate about 1 4 inch The worn surface should be rotated forward This will prevent the worn surface from coming in contact with paper that is being fed into the singulation point Auxiliary Feed Belt Adjustment The auxiliary feed belts are adjustable by angling the back end The ideal setting for the auxiliary belts is when the upstream up or down end is raised just above the main feed belt Turn the knob clockwise to lower the rear end of the auxiliary drive belts The auxiliary feed belts assist the main feed belt when Turn the knob counterclockwise to raise the rear end of variations in frictional characteristics are encountered an
132. on for 1 to 12 sheets Counter Modes Total count batch count resettable count Output Conveyor Options Version 1 with shingling output conveyor stacker 438 V4 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 Versions 2 with intelligent transfer conveyor interface to gripper arm of inserter s insert station Version 3 with a buffering intelligent transfer conveyor interfaces to an open feed station of inserter The GBR 438 3 can also convert an intelligent continuous form mail inserting system to a cut sheet operation Controller Adjustable operator s panel with readout and touch screen access to all system functions System is microprocessor controlled with self diagnostics and error display including double misfeed and jam detection Electrical Service 208 volts 3 phase Y 20 amp 4 pole 5 wire grounding use NEMA L21 20R 220 volts 1 phase 20 amp 3 pole 4 wire grounding use NEMA L14 20R 1 000 BTU hr Fuse List Refer to Section D10 Dimensions includes feeder accumulator folder and transfer conveyor Length 106 mm Width 26 mm Height 58 mm Weight Net approx 725 Ibs kg Read Options Line Code B H or GBR Bar Code INTRODUCTION SECTION A PAGE 12 5 RUN SCREEN e Status Displays machine status such as Power Off This screen is displayed continuously for informational purposes until Test or Setup is s
133. on refers to a bar code whose bars look like a ladder when facing the bar code s direction of travel Picket Fence appear as a picket fence when facing the direction of travel Regardless of the direction of travel the scan line must be perpendicular to the bars In some applications codes are printed on glossy paper or covered with a shiny material such as cellophane When this happens it is possible that the code surface reflects so much laser light that it is very difficult for the scan head to decode the bar code To avoid reflections from the surface of glossy bar codes do not mount the scan head parallel with the object to be scanned Mount the scan head at a five to ten degree angle so the laser beam reaches the bar code at a slight angle 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 INTRODUCTION SECTION A PAGE 43 A 10d Setting the 438 to Read Laser Bar Code GBR Systems Bar Read Setup b 5 Job Number Jo BAR USER SETUP 1 l Bar Read Test Reset Job Defaults 11 19 59 Powered Up 11 20 03 Barcode Setup Started 11 20 03 Barcode Setup Done Ready Setup Bar Read Modifications to the bar setups are retained as long as the bar job defaults are not restored or the internal non volatile storage is not overwritten by a new ini file or is lost SETUP 1 SETUP 2 SETUP 3 SETUP 4 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 Job Select the job to ru
134. ons after envelope insert station e Enter Point Option PT 1 Select Station 7 e Postal Meter 3 e Meter ON AT in degrees 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 e 10 Meter OFF degrees e 6 Meter Position STA 6 stations after envelope insert station e 2 Enter Point Option PT 2 Select Station 8 e Postal Meter Weights e 30 Meter 1 to 2 Weight Value e 20 Meter 2 to 3 Weight Value A 13b Two Meter Example Meter 1 to 2 Weight Break Value 99 Must be greater than any pack expected Meter 2 to 3 Weight Break Value 20 Package Weight Meter 2 Meter 3 6 11 19 20 26 31 Three Meter Setup Lineread Setup e Select Postal Meter Divert Enable OFF to operate from Weights ONLY Inserter Setup e Postal Meter By Weight Check ON to enable Postal Meters Inserter Setup 2 e Postal Meter Divert Postal Meter 1 e Meter ON AT in degrees e Meter OFF in degrees e Meter Position STA 0 disabled e 9 Enter Point Option PT 9 Postal Meter Divert Inserter Setup 3 e Postal Meter 2 e 200 Meter ON AT in degrees INTRODUCTION SECTION A PAGE 54 e 10 Meter OFF in degrees e 6 Meter Position STA 6 stations after envelope insert station e 1 Enter Point Option PT 1 Select Station 7 Postal Meter 3 e 240 Meter ON AT in degrees e 60 Meter OFF in degrees 6 Meter
135. op Subset By Count 2 l l I l Item Verify Fist Pg v Last Pg Off Item Verify Min 1 Max 4 l I Check Digit Mod 10A Mod 108 Mod43 None Process Status Ready Total Page Code Start 0 to 30 Start character Length 0 to 5 Number of characters Start Bit 0 to 30 Starting bit position within character Length Bit 0 to 30 Number of bits Sq Stop Code Start 0 to 30 Start character Start Bit 0 to 20 Starting bit position within character Subset Code Start Start bit 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 Unseal Code Start Start Bit Stitch Code Start Start Bit No Stop Max Errors Setting No Stop Max Errors to 0 allows the machine to function normally and stop on a read error Setting to 1 enables the No Stop function which when a read error is detected continues to process the job but the pack with the error is diverted at the end of the inserter This use of Divert has priority over Divert by Mark and Divert by Weight To use this function Bad Pack Stop Enable in Inserter Setup 1 must be deselected Priority Levels for Pm Divert are 4 No Stop if selected in Line Read and Line Read is selected in System or if No Stop is selected in Bar Read and Bar Read is selected in System If None is selected for read type then No Stop is disabled 5 Meter Divert in Line Read no matter what read type is selected 6 By
136. or right sides of the feeder By using a reflective beam to search for code marks a variable electronic signal is produced and sent to a proprietary electronic read board interpreting the variations in light intensity The double feed detect sensor is an ultrasonic device that will detect multiple sheets fed from the feeder Paper feeding is accomplished when the feed motor drives the belts An electric clutch engages the feed belt at a signal from the controller The optical encoder blue clad located on the right side of the upper pullout shaft monitors feeder run speed E 1B TIMING PROCEDURES Not applicable timing is a function of software and CPU E 1C FEEDER SETUP AND ADJUSTMENTS Paper Guide Rails These rails guide the paper from the hopper table through the singulator area and to the accumulator area without skewing The guide rails should be set so that with a single sheet of paper laying flat between them has a 1 16 inch space between the right and left edges of the sheet and the guide rails Please Make certain that the guide rails run parallel with the side frame of the machine Loosen the setscrews and the hanger bracket thumbscrews locking the rail blocks to the cross shafts to adjust these rails NOTE Be sure the side rails are feeding the paper parallel to the singulating roller 438 OPERATOR amp SERVICE MANUAL 071 XXXXX 400 ISSUE 2008 05 Creeper Conveyor Adjustment The position of the creeper conv
137. ors 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 PREVENTIVE MAINTENANCE 071 28558 401 SECTION B PAGE 1 438 OPERATOR amp SERVICE MANUAL 071 28558 401 B2 a2 Cleaning the Fold Rollers DO NOT USE ANY LIQUID ON THE FOLD ROLLERS The fold plates must be removed in order to clean all fold rollers Please use extreme caution when removing the fold plates They are heavy and expensive to replace B2 a3 Machine Cabinets and Covers Clean the machine cabinets and covers using a soft damp cloth B2 a4 Paper Hopper The feed belt should be cleaned with a fluid such as isopropyl alcohol that does not leave a film Apply some alcohol to a rag then lightly rub all dirt and film off the belts B2 a5 Singulator The Singulator must be as clean as possible at all times to insure the proper feeding and singulation of paper by the feed belt This may be done first making sure that the singulator is not worn If so loosen the small set screw on the operator side and rotate the roller to a point where a rounded spot on the roller will contact the paper NOTE If there flats completely around the roller and no rounded spot available the singulator roller should be replaced as soon as possible Once this is accomplished raise the singulator roller approximately 3 4 from present setting Pass an alcohol dampened rag under the bottom of the singulator roller Be sure that it is making sufficient contact to clean away all dirt and debris f
138. osition from varying too much It is important that the packages in the transfer conveyor do not vary so as to throw off the timing of the ejection E 4h Transfer Conveyor Package Spacing Problem If a package spacing problem occurs in the transfer conveyor it should be purged of all the remaining documents in it This will reset the package positioning ADJUSTMENTS amp REPAIR INFORMATION SECTION E PAGE 32
139. otal Page Each sheet has a page number and the total number of pages for it s group Select Total Up or Total Down in Page Sequence Read First The first sheet Banner Page of the document is read The page count information is used to determine how many more sheets to feed and not read After the last non read sheet is fed the next fed sheet will be scanned by the barcode reader to process the next document group BOG Mark Relates to first page hold 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 Group Chg Relates to first page hold Custld Chg Relates to first page hold Group Seq Purpose Identify each page as being a part of an individual package The sequential incrementing of the number ensures the documents printed sequence is maintained Up Match in set Min to Max to Min Down Match in set Max to Min to Max Matching Match in set Must change each set Same ID Match in set No change needed None Min 0 to 1 Max 0 to 99999 Max Keypad may be used to set a Max value through a keypad instead of using the arrow scroll button Page Seq Purpose Identify each individual page within a package The sequential incrementing of the number ensures the documents are assembled in the proper order Page Up Min to Max within sets Page Down Max to Min within sets Roll Up Min to Max to Min across sets Roll Down Max to Min to Max across sets Total Up A Z Supports Tota
140. p SERVICE MANUAL ISSUE 2008 05 ADJUSTMENTS amp REPAIR INFORMATION 071 XXXXX 400 SECTION E PAGE 21 The Fold plates and deflectors have a hand locking screw 1 each on the left hand and right hand side Insert the fold plates and deflectors in such a way that the locking screws 1 fit in the recesses 2 in the frame of the fold unit Secure the fold plates and deflectors by tightening the locking screws Loosen the lock screw for the paper stop 3 Set the stop to the required position on the scale 5 by turning the adjustment wheel 4 Secure the fold plate stop by tightening the locking screw 3 By turning the fine adjustment screw 6 the fold length can be fine adjusted with the machine running By turning the knurled knobs of the adjustment wheel 1 it is possible to make angle corrections of the paper stop For example if the paper is out of square The combination fold plate of a MM 438 has an infeed section with an adjustable lower lip This means the space available to form the buckle can be modified depending on the thickness and the stiffness of the paper The lower lip is moved by turning a fine adjustment screw 2 that is equipped with a scale 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ADJUSTMENTS amp REPAIR INFORMATION 071 XXXXX 400 SECTION E PAGE 22 Type of fold Fold length Fold plate setting DIN A4 DIN A3 210x 297 297 x 420 e For difficult to handle paper it is possible
141. paper slippage This means the integrity of the Line Code information must be ensured by the data fields represented within the code A Low Tolerance interpretation of a line code synchronizes the print line windows on the Gate Mark The Print lines following the Gate Mark are divided into absolute locations When a mark is detected it is automatically associated with a Print line number This means the Line Code Recognition system will not look for the standard tolerances applied between Line Code marks When High Tolerance read is selected the print line windowing scheme applies the standard tolerance specification between Line Code marks This makes it likely for paper slippage in the machine to be detected during the interpretation of the Line Code Detecting paper slippage improves the integrity of the Line Code Recognition process It also introduces the possibility of more reading errors being created A High Tolerance interpretation of a line code synchronizes the print line windows on the Gate Mark The Print lines following the Gate Mark are divided into zones of 1 2 print lines Centered around the expected location of every Line Code Mark is a 1 2 print line zone where the Line Code mark is expected to be detected Between two Line Code marks there is a 1 2 print line zone where a mark can not be detected without creating an error This ensures that all Line Code marks are exactly where they are expected Press OK 438 V4 OPERATOR
142. present the letters and numbers The figure below shows each part of a bar code The labels for each part remain the same even if the position orientation or type of bar code changes 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 Wie Width The GBR 438 with the Microscan MS 911 uses the 3 of 9 code or Code 39 fixed or variable length This was the first code developed that used both numbers and upper case letters It is the most recognized and widely used for non retail applications Each character is represented by a stand alone group of 5 bars and 4 spaces The basic code set includes 0 9 A Z which is used for the start and stop characters and six other symbols and 96 for a total of 43 characters Because each of the characters are discrete and self checking Code 39 provides a high level of data security The Microscan MS 911 automatically checks all data for this symbology The bar code width must not be printed smaller than 0 010 025 mm Recommended width is 0 015 code height is 3 8 inch Minimum quiet zone start and end of 25 inches Bar coding sizing tolerance ratio tolerance per ANSI MH10 8 1983 Print quality must meet or exceed ANSI Grade B per ANSI X3 182 BAR CODE PRINT QUALITY GUIDELINE INTRODUCTION SECTION A PAGE 42 A 10c Adjusting Your Microscan MS 911 Your scanner can be mounted in any direction depending on the scheme of your bar codes Ladder orientati
143. pressing Line Calib make sure Reader Type Line in System Setup screen is selected Read must be selected in Feeder Setup and all sensors must be properly adjusted All Line Read Setup screens must be setup Select Calibration On in Line Read Setup 2 before starting and Off when finished Get Version Pressing this button results in printing the software version of the LineReader on one line of the Monitor Events window B H Sensors Note For use with either B H or GBR Line Read Enables viewing the action of the sensor signals for diagnostic purposes Monitor Events Window It is intended to give the operator or technician feedback regarding the status of what is occurring select a job number set all settings for the job in Line Read Setup 1 2 and 3 438 V4 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 INTRODUCTION SECTION A PAGE 21 A 7h Bar Read Setup 0 Refer to Section A for setup information A 7i Setup 0 GBR Systems Inserter Setup 0 Inserter Protocol T v Inserter Postar Setup 1 Setup 2 sou Selection Direction v 6101 1106 Setup 4 Postal Meter By Weight Enable Degrees 160 Home 1 Demand State 0 Avg Dmd Rate 0 ON Deg 0 OFF Deg 0 Inserter Monitor 10 06 56 Powered Up 10 07 01 6000 5000 4000 3000 2000 1000 0000 0000 Ready Setup 1 Inserter Type amp Feature Selection Setup 2 Inserter Station Feature amp Setup Setup 3 Postal M
144. q grouping and the Page Seq grouping must be located as sets however Probes A B Select the reading probe to be used Bit Weight Page and Group marks can be arranged as Most Significant Bit First MSB or Most Significant Bit Last MSB First is the first bit encountered when reading MSB Last is the last bit encountered when reading Example MSB Last Example MSB First GRM GRM EOG EOG GS1 GS8 GS2 GS4 GS4 GS2 GS8 GS1 PS1 PS4 PS2 PS2 PS4 PS1 PAR PAR INTRODUCTION SECTION A PAGE 36 GBR Line Code Calibration NOTE Calibration is normally to be used by the service technician only See section GBR Line Code Read for related information See Line Read Setup 0 Line Calib for B H Line Read calibration The GBR Line Code Recognition system can be calibrated to the particular machine in which it is installed Calibrating the Line Code Recognition system to the particular machine eliminates parts tolerance problems and provides a method of recalibration once parts have become worn Calibration of the machine is provided for 1 10 1 8 and 1 6 code spacing There is a different calibration number stored in battery backed memory for each type of code spacing This means a machine must be calibrated when the proper line code spacing is selected Once a machine has been calibrated for 1 6 1 8 or 1 10 spaced codes it will operate properly until the parts on the machine become severely worn The machine is calibrated by
145. r within the time frame set in engineering values D 7 ANALYSIS D 7a Troubleshooting the GBR Line Code Reader e The pullout rollers the rollers that are right after the singulator should be adjusted such that they evenly grip the paper as it moves through Rip off two strips of paper and place the paper on each side of the pullout rollers Turn the rollers by hand and make sure that the two pieces of paper feed through evenly If the paper does not feed through evenly use the adjustments on the sides of the roller shaft to adjust the rollers D 7b Physical Specifications of the Line Code System The Print Contrast Ratio should be at least 6596 Mark size specifications Minimum length of solid mark 0 3 recommend 5 Minimum width of solid mark 0 015 recommend 020 Maximum width of solid mark 0 030 Clear area specifications 0 064 when using 1 8 line spacing and 0 094 when using 1 6 line spacing minimum clear area between marks taking into account print registration and maximum function line size Clear area required on each side of marks 0 2 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 Clear area required at the lead edge of the Gate mark 0 332 Clear area required at the trail edge of the code 0 166 Code location on paper Measured from the leading edge of the form the code should be placed on the first 1 3 of the form The Gate mark registration must be held to 1 print line 0
146. rom the contact portion of the singulator roller ISSUE 2008 05 PREVENTIVE MAINTENANCE SECTION B PAGE2 B2 b LUBRICATION No lubrication is required on the 438 NOTE If a mechanical component is out of line or deformed a small amount of oil may be used as a short term fix to eliminate noise or binding until the component can be replaced SECTION C ELECTRONICS SECTION C ELECTRONICS 1 C 1 LEFT SIDE VIEW MAIN CABINET ELECTRONICS CABINET ASS Y 005 28579 501 2 C 1 RIGHT SIDE VIEW MAIN CABINET ELECTRONICS CABINET ASSY 005 28579 501 3 C 2 DC POWER DISTRIBUTION CHASSIS 4 E STOP amp INTERLOCK BOARD ASSEMBLY 6 C 4 COMPUTER CHASSIS ASSEMBLY 196 31487 500 7 C 4a CPU Controller SAT 520 l usss eene 8 CAD Daughter Card i aaa aaa hiaan petet 8 C 5 AC DISTRIBUTION ASSEMBLY 502 31475 500 9 C 6 INTERCONNECT BOA RD 042 31483 500 10 7 RACKS PORT 0 1 AND 2 11 C 8 SINGLE CHANNEL READ CARD 12 C 9 LINE CODE READ CHASSIS
147. rrupt communication is done in the following manner 1 Clear transfer conveyor of all documents 2 Place a folded document approximately 1 2 inches before the Exit sensor on the transfer conveyor NOTE Be sure the inserter is running to supply a demand signal 3 Run the 438 and command the machine to dump 4 The Transfer conveyor will index in response to the dump command If the package that was placed just before the exit sensor stops at the discharge end of the Transfer conveyor the interrupt is being seen by the control card However if the document is passed out of the end of the transfer conveyor then the interrupt is not being seen by the control card NOTE See opto 1C3D4 Interrupt signal ISSUE 2007 09 ADJUSTMENTS amp REPAIR INFORMATION SECTION E PAGE 30 E 4d 438 Configuration of Exit Sensor Module The Exit sensor amplifier module on the transfer conveyor has an active state selection switch on it This switch can be set to LIGHT ON or LIGHT OFF The proper position for the switch is LIGHT ON Transfer Conveyor Exit Sensor Figure SENSOR MODUL EXIT SENSOR E 4e Package Overhang at insert Station When a package is being presented to the gripper arm furthest station from the stuffing station the package should have only the trailing edge of the folded document
148. se values are not obtained go to section A 8b and reset the Offset 2 At 109 Trip Pt At 51 Trip Pt2 At 153 probe 9 Find the average of the recorded OFFSET 1 and 2 values 10 Change OFFSET 1 and 2 value to this average value by E o pressing the or keys example OFFSET 1 129 OFFSET 2 M 111 average 120 set both OFFSET 1 and 2 2120 11 Change GAIN to 0 Line Read Monitor 12 Record these settings in the area to the right In the future this 11 19 59 Powered Up procedure can be eliminated by entering these values directly 13 Press APPLY to download these parameters to the read system and then press OK 14 The reader setup is complete Line Read screens SETUP 1 2 and 3 must be completed before running paper NOTE When switching between probes or after the 438 has been switched Process Status off it may be necessary to repeat this setup procedure Ready NOTE VALUES FOR FUTURE REFERENCE To find the values go to Setup gt Line Read gt Setup 4 and write down Note This screen is used only for B H Line Read not used for GBR Line Read ead the values listed there 1 Turn on the 438 press the SETUP button then press the LINE GAIN READ button i 2 Select GBR 3 Press OK OFFSET 1 4 Press LINE READ again 5 Press SETUP 4 RE a Take a piece of the stock that is going to be run through the machine and hand feed i
149. sert Station 0 When set to 0 the station is always off When set to 9 the station is always on If a station is down the next station in line can be programmed to take its place e Station Setup 1 4 e Station Setup 5 8 Demand Degree This is similar to setting dwell time on an engine As the speed of the machine is increased home may be programmed at a position prior to 0 degrees allowing for lag time in components at higher speeds Degrees may be set for 0 thru12 000 cycles per hour in 2 000 increments Note Inserter degrees are reset to zero at the occurrence of a home pulse for either inserter encoder INTRODUCTION SECTION A PAGE 23 A 7k Inserter Setup 2 Insert Station Vacuum is normally enabled at 100 This is the position of the encoder in degrees at which vacuum is applied to the insert station GOR Systems Inesrtsr Setup 2 Logical Shift is normally set to On At 90 This is used to carry the data bpm Pen At 230 Station 2 with the physical document LR Bs Bad Package Stop is normally set to On At 80 Env Flap Detect OnAt 10 OfAt 350 Station 1 Kicker The Kicker routine is initiated by the extraction of an Ink Mark from I I l read data Time Normally set to On Time period of time in milliseconds that i 7 i i the Kicker will be ON or energized SANE ais Delay Period of time in milliseconds to delay the Kickers ON time from PM Divert OnAt 10 OfAL 1
150. son an error is flagged CHECK VALUE The value being used to flag the error Some are calculated based on speed sheet length etc ADJUST VALUE Where the check value can be adjusted ERROR CODE SECTIONS e 11xxx System Messages 12xxx Feeder Messages 13xxx Accumulator Messages 14xxx Folder Messages 15xxx Xfer Conveyor Messages 16xxx Barreader Messages 17xxx Inserter Messages 18xxx Linereader Messages 19xxx EngValue Messages 20xxx COMMPORTS3 Messages 21xxx InFeed Messages An 8 in the third digit position is the same as a 0 Example 18836 is the same as 18036 D 6a Error 11820 11821 11822 11824 11xxx System Errors Description Exit Demand Timeout Purpose Waiting for a Demand from the inserter EVENT Accumulated Package Ready to Exit Demand EVENT CHECK ExitDemandTimer CHECK VALUE 60 sec ADJUST VALUE Engineering Value 21 Cause The Time window for Event to occur 60 sec had elapsed setting the error Cover Interlock Open or Emergency Stop Set See Table at end of section for locations of interlocks EVENT Interlock ON EVENT CHECK Interlock CHECK VALUE ADJUST VALUE ANALYSIS Interlock ON at power ON Cover Interlock Open or Emergency Stop Set EVENT Interlock ON EVENT CHECK Interlock CHECK VALUE ADJUST VALUE ANALYSIS Interlock ON at machine powered Exit Sensor Error Purpose EVENT Exit Demand EVENT CHECK
151. ss 22 E 3i Setting the Fold Roller Gap seem 23 E 3j Fine Adjustments and Corrections esee 24 E 4 TRANSFER CONVEYOR 29 E 4a Description ena e a ees 29 E 4b Timing sue n Hee eT Heus 29 E 4c Exit Sensor Test on the Transfer 30 E 4d 438 Configuration of Exit Sensor Module 30 E 4e Package Overhang at Last Station esses 31 E 4f Transfer Conveyor s Outfeed Guides Position 31 E 4g Fold Quality si DUREE 32 E 4h Transfer Conveyor Package Spacing Problem 32 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ADJUSTMENTS amp REPAIR INFORMATION 071 XXXXX 400 SECTION E PAGE 1 438 OPERATOR amp SERVICE MANUAL 071 XXXXX 400 ISSUE 2008 05 E 1 FEEDER E 1a Description A paper hopper Creeper Conveyor supplies the bottom fed friction feeder continuously while the operator loads paper from the top It has 4 mounts 2 each side with set screws in which the hopper slides The creeper conveyor is comprised of two black rubber belts driven by a motor located on the bottom side of the hopper Controlled by a paper level detector the motor is activated when the Paper Demand Wand activates the paper demand switch The two stainless steel paper guide rails mounted on the hopper are adjustable via a locking handle at the rear At the front t
152. stal meter doesn t place the postage in the correct place Postal Meter 2 found in Inserter Setup 3 should then be set to 40 higher than the new meter 1 value and Postal Meter 3 should be 40 higher than 2 OFF at xx should be set to 10 for all three Station 0 is set to the value of the last chain section of the inserter after the envelope stuffer and the turnover 04 05 06 07 etc this is normally set to 07 on a six station inserter Point xx selects the postal meter output line to the 438 this is normally set to for PM Divert 1 for Postal Meter 2 and 2 for Postal Meter Weight Breaks The 438 will total the weights of all documents inserts and the envelope and then send it to the correct postal meter Because you are setting the weight breaks as well as the envelope page and insert weights it is important to keep the unit of weight i e oz consistent 1 2 Enter the Weight Break of Postal Meter 1 to Postal Meter 2 2 3 Enter the Weight Break of Postal Meter 2 to Postal Meter 3 Page Env Wts Page Enter the weight of the individual page the 438 will sum the weight of all pages automatically Env Enter the weight of an individual envelope Ins 1 4 Wts and Ins 5 8 Wts Enter the weight of each insert in stations 1 4 and stations 5 8 Refer to Section H 4 for an example of a Typical Postal Metering Setup Preset INTRODUCTION SECTION A PAGE 25 A 7m Inserter Setup 4 GBR Systems Ins
153. t each additional channel requires another Line Code Recognition system Read Probe Assembly START READ SENSOR 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 INTRODUCTION SECTION A PAGE 32 A 9b 438 Line Read Setup Screens GBR amp B H GBR Systems Line Read Setup 0 B amp H GBR GBRCode8 GBRCode16 Job Number Job 5 Line Read Code 5 Reset 1 Line Get B amp H ProbeA EdgeA ProbeB Edge B Calib Version Sensors 0 0 0 0 Monitor Events 10 06 56 Powered Up 10 06 57 LineReader STDBUS Interface Only 10 06 57 LineReader GBRCodeSTB Interrupt Disable 10 06 57 LineReader GBRCodeACK Interrupt Disable 10 07 01 Lineread Setup Started 10 07 01 Lineread Setup Done 10 07 02 LineReader Software Version 08103 003 12 54 16 E 1 G 1 P 0 T 0 Z 0 D 0 1 000000000000 L 1100010001000000000 Ready Line Read Setup 0 Select the type of Line Code to be read e B amp H GBR GBRCode8 GBRCode16 Select the Job by paging through the Job Numbers and picking a previous job or enter a new job Select the desired Probe 438 V4 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 A 9c Line Read Setup 1 GBR Systems Line Read Setup 1 Demand Feed Normal Reverse Yes No First Page Last Only v 1st Only Tti Pg Group Seq Up Down Matching 10 v None Page Seq Page Up Page Down Roll Up RollDown Item Count Total Up Total Dn None Parity Mark Odd Even None Seq S
154. t until the light beam is on a white TRE CONT portion of the paper b Press WHITE The system will indicate that when it is done 2 6 Press BLACK and slowly move the paper until a black bar is under the light 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 INTRODUCTION 071 28558 401 SECTION A PAGE 41 A 10 LASER BAR CODE READ OPTION A 10a Laser Safety The radiation level from the laser does not constitute a health hazard Exercise care to avoid any unnecessary direct exposure to the eyes Avoid staring at the light source since prolonged exposure could result in eye damage Avoid deliberate eye exposure to the beam Inadvertent contact however is not a cause for alarm Any service should be performed so as not to violate compliance with the Code of Federal Regulations Title 21 Part 1040 Section 10 21 CFR 1040 10 as administered by the Center for Devices and Radiological Health a service of the Food and Drug Administration under the Department of Health and Human Services Do not attempt to defeat any safety provisions A 10b Bar Code Basics A bar code is a group of rectangular bars and spaces arranged in a preset pattern The pattern is organized to represent elements of data referred to as characters The standard industry codes can represent several alphanumeric characters There are many different types of bar codes Each type uses its own symbology which defines how the bars and spaces re
155. ted in System or if No Stop is selected in Bar Read and Bar Read is selected in System If None is selected for read type then No Stop is disabled 2 Meter Divert in Line Read no matter what read type is selected 3 By Weight is default Press OK IMPORTANT NOTE Press Cancel to void any changes made to this screen or OK to set the changes and return to the Line Read Setup 0 screen 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 INTRODUCTION SECTION A PAGE 35 A 9d Line Read Setup 2 Setup gt Line Read gt Setup 2 GBR Systems Line Read Setup 2 Lines Inch v 6Lpi 8 Lpi 10 Lpi Probes A B v ProbeA Probe B Bit Weight MSB First MSB Last Calibration v Off On Tolerance v Low High Ready Lines Inch The code marks can be at 1 6 1 8 or 1 10 inch spacing This is 6 8 or 10 lines per inch There can be as many as 25 mark locations in a bank EXAMPLE GRM Gate Mark EOG End of Group GS1 Group Seq Bit 1 GS2 Group Sea Bit 2 GS4 Group Seq Bit 4 GS8 Group Seq Bit 8 PS1 Page Seq Bit 1 PS2 Seq Bit 2 PS4 Page Seq Bit 4 PAR Parity 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 NOTE Presence of a bar is binary 1 and the absence of a bar is binary 0 The GRM mark must be located in the first position The EOG PAR Group Seq number and Page Seq number marks may be shifted in the bank of marks The Group Se
156. the CPU card and external inputs and outputs Configuration Floppy Disk Port 3 TP Printer Port Jumpers as shown in diagram J1 to touch screen J1 to RS232 connector on cabinet bulkhead J16 to floppy drive COM 2 Serial Port Touch Screen Port SVGA Port ONOAPR WN C 5 AC DISTRIBUTION ASSEMBLY 502 31475 500 Power Supply Conn amp On Off Sw er Power amp On Off Sw 438 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 ELECTRONICS SECTION C PAGE 9 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 10 C 6 INTERCONNECT BOARD 042 31483 500 7 Sto i i wemmeamamemmamyi Y nw Accumulat a ME nues Suus Connector T EET E n i Y i ference 5544 inserter Connector Cutter 3208 Connector mnn um Ink marker Son Connector EAN V SH E onnector abu Stk F s Cp EE WPW 73143390 e Lu u i M Sa ER D amp C 7 OPTO RACKS PORT 0 1 AND2 Or n 5 gt S Cal n 1 7 eee t ACAD O8 P mL BARSARA S yr 4 ais LN 1 m E e 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 The opto racks hold the input and output modules and transfer their signals to and from the opto board via ribbon cables plugged into their respective headers The
157. the group is not out of sequence check to see that the proper barcode is printed on the page and that the barcode matches the specifications Check to see that the proper barcode job is selected If page sequencing down and the last page fed was page 1 the software expects the next page to have an end of set mark on it new set and highest page of that set or if 6 pages are fed into the accumulator the software expects the next page to have a subset mark or an end of group mark on it If an end of group mark was present check to see that the proper barcode is printed on the page and that the barcode matches the specifications Check to see that the proper barcode job is selected ISSUE 2008 05 REPAIR INFORMATION SECTION D PAGE 17 438 OPERATOR amp SERVICE MANUAL 071 28558 401 nn003 BLANK PAGE nn004 SHORT GROUP nn005 DUPLICATE PAGE 006 PAGE OUT OF SEQUENCE nn007 INVALID GROUP ISSUE 2008 05 REPAIR INFORMATION SECTION D PAGE 18 No code detected Check read setup again particularly focus Check for correct feed speed Check speed sensor for proper operation Check for failure on the CPU replace as necessary Bad UARTSs Bad software Check the page to determine if error is valid Check read setup again particularly focus Check for correct feed speed Check speed sensor for proper operation Check for failure on the CPU replace as necessary Bad UARTSs Bad software
158. the reader encoder is returning good data If data is inconsistent replace the reader encoder An invalid calibration error indicates that the calibration reading was more than 15 different from the expected stored result 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 PROBLEM ANALYSIS SECTION D PAGE 3 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 PROBLEM ANALYSIS 071 28558 401 D 2 INITIAL ACTIONS Ask the operator to describe or demonstrate the problem Request all information on the failure If there is an error message refer to the index for guidance to appropriate Repair Correction Procedures Some features of the machine may not be tested during the system checks and therefore operator input will be a valuable asset to help diagnose the total system If the problem is the result of improper operator action refer the operator to the operator documentation or instruct the operator on the proper actions Switch the 438 AC power OFF Check all areas of the machine for paper or other obstructions including inside the Folder Remove any paper or obstructions and feed a sheet through the machine to confirm that alignment adjustments are correct Turn ON the 438 press RESET then Start Stop and confirm the following e All drive belts are moving e Sensors are not blocked or fouled e Machine operating parameters set correctly e Document inserted in paper hopper passes through and is properly fol
159. to a one when the inserter is at home position Demand State Operates in Demand Type Switch or Degree see Inserter Setup 1 3 ON 0 OFF Average Demand Rate Diagnostic averages Demand Rate over three cycles ON Degrees Degrees where demand goes on by either Switch or Degree demand OFF Degrees Degrees where demand goes off by either Switch or Degree demand Inserter Monitor Prints events INTRODUCTION SECTION A PAGE 22 A 7j Inserter Setup 1 GBR Systems Inserter Setup 1 Ins Stations 4 4 6 4 4 Xfer At Stations 2 Xfer Type V Open Encoder 100 36 l Gripper Logic 775 AC DC Demand Switch Degree Serial Bad Pack Stop Subset None Pause Remove Station Setup 10 29 3 0 40 1 l 1 1 I 1 l Station Setup 50 6 0 7 0 8 0 l I 1 1 I l Demand Degree Rate x1000 0 2 4 6 8 10 12 ONDeg 0 350 330 310 290 270 250 1 l Window 80 90 110 110 100 100 BO Ready Ins Stations 4 6 4 4 Choose Inserter configuration Xfer At Stations e Select 0 for GRIPPER 1 9 for Open feed e Normally set to GRIPPER Inserter takes the folded document from the 438 e Select OPEN FEED when the 438 will be placing the folded documents directly on the inserter track When using open feed selected number represents the number of stations prior to the first insert station the package was placed Encoder Type e 100 Tick or 36 Tick Logic Type e 775 420T 438 contro
160. to set back the complete fold 1 148 1 210 plate by up to 4 mm For this two o 2 0 2 0 allen screws 9 have to be loosened d a E at the left and right side of the fold fold plate A scale 10 facilitates precise setting E 3g Close Fold Plate MM 438 1 198 1 280 Letter je i en fold 4 0 4 0 If the fold plate is not used and must therefore be closed it can stay in the fold unit e Set the fold plate stop to the maximum fold length highest position by turning the setting wheel 1 e Continue turning the adjustment wheel against a slight is resistance until the stop is reached now the deflector has 2 10 2 14 Accordion 3 0 3 0 closed the opening to the fold plate 2 fold 4 0 4 0 E 3h Setting the Fold Length The type of fold determines the position of the fold plates and deflectors ase The unfolded format determines the fold lengths to be set n 2510s The fold length is the distance between paper stop and fold p line For accordion folds fold plate stops should be set so they increase by 1 mm from one fold plate to the next Setting Guide for Common Types of Fold E 3i Setting the Fold Roller Gap Each folder is equipped with a paper thickness caliper 1 Before setting the fold roller gap clamp the respective paper between the rollers and read the paper thickness of the scale The fold roller gap is set by means of setting screws which are numbered R
161. ul v LJ y LJ Ub o D u ve g 5 2 a 23 2 Au a MATL FNSH JNLESS OTHERWISE SPECIFIED DMENSIONS ARE IN INCHES N GBR STEMS CORPORATION H x 12 INSPIRATION LANE CHESTER CT 06412 7 J TEL 960 526 AND UDPERAROE TITLE DRAWN I INTERCONNECT RACK PORT 1 REMOVE B EDGES amp CHECKED THIRD ANGLE PROJECTION YL SUR PER 59 315 0 308 ED SCALE 44 SHEET 4 OF INTERPRET Di NG PER ANSI Y14 3 1 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 33 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ELECTRONICS 071 28558 401 SECTION C PAGE 34 7 B 597 31570 309 REVISIDNS ZONE REV DESCRIPTION DATE APPROVED ORIGINAL RELEASE 9394 08 15 06 EJH NAD 1 TO CREEPER MOTOR CONTROLLER 24V RET VD O fo a I soo 2 E gt gt Bu 3b dog n AK MOD 1l us JPR Nia O30 30 D OUTI3 16
162. velope bits are set to zero 1 Upon Bad Pack select and envelope bits are retained 438 V4 OPERATOR amp SERVICE MANUAL 071 28558 401 ISSUE 2008 05 INTRODUCTION SECTION A PAGE 30 Number Value Description Number Value Description 46 1 Accum Pack Bad Set Previous Pack Bad Also 53 0 Inserter Error Pause mode Switch Range 0 gt 7 Range 0 gt 1 Inc 1 Default 1 Inc 1 Default 0 1 Default Upon occurrence of a bad pack the 0 Default Normal operation previous pack processed is tagged as bad pack also 1 Pulse I O 1 16 upon a read or processing error pack in Xfer conveyor 2 Pulse I O 1 16 upon a Demand Feed occurrence 0 Previous pack if no error in normal processing is while accumulating a package not tagged as a bad pack 3 combines functions 1 amp 2 m z is 4 Steady state on I O 1 16 upon a Demand Feed 47 0 BEN o hus 1 Invert 0 Normal occurrence while accumulating a package quiu S 5 combines functions 1 amp 4 0 Default Normal operation 6 Illegal combination 1 Logic inversion for the signal Incserco mailcrafter 7 Illegal combination 48 0 Intrack Sns Method 0 1 Subset pause Range 0 gt 1 Inc 1 Default 0 0 Default Normal operation 1 Support for Subset Pause operation utilizing both Transfer Conveyor out Sensor and Intrack Open Feed Sensor to track folded subs
163. will complete the package containing the last sheet Package Select job size by entering the number of packages to run When selected the Batch Off button changes to Set Packs Off Disables Batch Processing Batch Off Button Changes to Set Packs or Set Sheets depending on the option selected Press to enter batch value a numeric keyboard is displayed then press to set Batch value is displayed to the left of the button This button is not available when Batch Processing Off is selected INTRODUCTION SECTION A PAGE 16 A 7b Feeder Setup GBR Systems Feeder Setup Double Detect Off Optical X Ultrasonic Pulse Feed Off Page End Timed Read Pulse Feed Time 400 l Ready Double Detect Enable Select to have the 438 detect double feeds Optical is a thru beam sensor whereas Ultrasonic detects the interference of air between two or more sheets fed Deselect if paper stock is causing false double detects Pulse Feed Deselect to engage clutch for the entire pack AKA Stream Feed When selected the feeder will place a larger gap between the sheets by turning the clutch on and off for each page fed Page End Clutch is off at lead edge of page on again at trail edge of page 438 V4 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 071 28558 401 Timed Pulse Feed Time must be set when using this option Clutch is off at lead edge of page on after Time for Tim
164. wo thumbscrews that latch the feeder to the accumulator 4 Loosen the accumulator to feeder drive belt tensioner and remove belt 5 Move feeder out of way 6 Remove both accumulator side covers 7 Remove the lower fold plate sliding cover by first removing the two stop screws on the slide track ADJUSTMENTS amp REPAIR INFORMATION SECTION E PAGE 10 8 Remove the green drive belt going from folder to accumulator 9 Carefully remove all wire ties for left side folder to accumulator terminal block wire bundle 10 Prepare a table to use for supporting the accumulator whose top is within 3 of the bottom of the accumulator 11 Remove the two nuts that secure the accumulator to the folder 12 Carefully pivot the accumulator onto the table beside the folder E 2d Accumulator Shaft amp Bearing Replacement Removal of Covers 1 Remove power and the lexan accumulator cover Separate from feeder section 2 Remove glide track screws to facilitate removal of bottom cover 3 Remove accumulator right side cover by removing bottom screws Place hardware in a safe place 4 Remove knob by loosening its socket head cap screw and left side cover by removing bottom screws Place hardware in a safe place 5 Remove end caps on both sides Screw to be removed for removal of bottom cover Knoh tn he removed 2 438 OPERATOR amp SERVICE MANUAL ISSUE 2008 05 ADJUSTMENTS

438A Folder / 438B Feeder V4 Service Manual

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