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DS-1000/1200 Advanced Troubleshooting Guide

1. 439 494 Page 63 495 501 Page 64 502 509 Page 65 510 517 Page 66 518 525 Page 67 526 550 Page 68 551 602 Page 69 603 609 Page 70 610 615 Page 71 616 624 Page 72 625 700 Page 73 701 757 Page 74 758 764 Page 75 765 772 Page 76 773 1002 Page 77 1003 1021 Page 78 1022 1027 Page 79 1028 1041 Page 80 1042 1052 Page 81 1053 1057 Page 82 1058 1998 Page 83 Page 2 Error Code 1 2 Error Message Epot error Covers Open Wrong version of vertical stacker firmware detected Thickness checker offset is non zero Thickness checker failure No thickness checker data found Recovery Information Call Technical Support Close covers and press start to continue An incompatible version of VS firmware is fitted Please upgrade to the latest version as soon as possible Check Remove any envelopes under the thickness checker device Press Run to continue Thickness checker has detected the filled envelope is too thin Remove the envelope from the output area and manually check The job being run has NO thickness checker calibration data Please run the calibration process before continuing Operator action if fault persists Call Technical Support Ensure all covers are firmly closed If a particular cover will not close move the cover sideways and watch the screen to see if it momentarily closes If so then the alignment is out or the magnet is we
2. Check sensor functionality Check exit and closer sensors for moisture ingress Replace if moisture is present Check sensor cables are located away from any source of electrical noise DC motor Check operation of the divert solenoids and the pressure chassis Check operation of the divert solenoids and the pressure chassis Check operation of the divert solenoids and the pressure chassis Page 46 Error Code 250 251 252 253 254 255 Error Message No reader data group in Collate No reader data group in Divert 1 No reader data group in Divert 2 No reader data group in Fold OMR No reader data group at Shuttle No reader data group at Output Recovery Information Remove group from Collate and correct manually Remove group from Divert 1 and correct manually Remove group from Divert 2 and correct manually Remove group from Fold OMR and correct manually Remove group from Shuttle and manually correct Check envelope contents before continuing Operator action if fault persists Ensure scanner is correctly aligned to marks and calibrated for OMR Ensure marks are to company barcode or OMR specifications Ensure scanner is correctly aligned to marks and calibrated for OMR Ensure marks are to company barcode or OMR specifications Ensure scanner is correctly aligned to marks and calibrated for OMR Ensure marks are to company barcode or OMR specifications
3. Engineer action if fault persists Re check operator action before assuming there is a fault a Check that the divert lifts and falls freely and that envelopes pass freely along the through path b Check value of eject sensor clear and blocked c Check conveyor belts are running freely Re check operator action before assuming there is a fault a Check that the divert lifts and falls freely and that envelopes pass freely along the through path b Check value of eject sensor clear and blocked c Check conveyor belts are running freely Ensure hardware configuration is correct i e a divert conveyor is fitted to the divert unit a ensure that the divert backstop setting is not too tight approximately 2mm float on envelope width use twiddle screen to adjust if necessary b Ensure back stop is adjusting to the same position every time c Check value of divert sensor clear and blocked d Check solenoid adjustments are correct to provide sufficient lift to allow envelope cleanly into divert e Check divert conveyor pulses correctly and that conveyor belts do not slip Ensure hardware configuration is correct i e a divert conveyor is fitted to the divert unit a ensure that the divert backstop setting is not too tight approximately 2mm float on envelope width use twiddle screen to adjust if necessary b Ensure back stop is adjusting to the same position every time c Check value of divert sensor clear and blocked d
4. Ensure scanner is correctly aligned to marks and calibrated for OMR Ensure marks are to company barcode or OMR specifications Ensure scanner is correctly aligned to marks and calibrated for OMR Ensure marks are to company barcode or OMR specifications Ensure scanner is correctly aligned to marks and calibrated for OMR Ensure marks are to company barcode or OMR specifications Engineer action if fault persists a Check functionality of scanner in test mode b Check functionality of tacho and trigger for OMR using the lights on the OMR Barcode PCB c Ensure OMR Barcode conveyor belts are locked to the drive shafts and driving without slip Ensure that the feeder on line unit side guides are sufficiently tight to control paper within 1 to 2mm a Check functionality of scanner in test mode b Check functionality of tacho and trigger for OMR using the lights on the OMR Barcode PCB c Ensure OMR Barcode conveyor belts are locked to the drive shafts and driving without slip Ensure that the feeder on line unit side guides are sufficiently tight to control paper within 1 to 2mm a Check functionality of scanner in test mode b Check functionality of tacho and trigger for OMR using the lights on the OMR Barcode PCB c Ensure OMR Barcode conveyor belts are locked to the drive shafts and driving without slip Ensure that the feeder on line unit side guides are sufficiently tight to control paper within 1 to 2mm a
5. Operator action if fault persists Check that all paper is removed from the collator Clean all sensors using an air duster Check that all paper is removed from the collator Check adjustment of side guides is not too tight Clean all sensors using an air duster Ensure all springs are in contact with conveyor belts with a light pressure Increase tension where necessary by tightening the M4 cap head screw for each spring assembly Check that program matches paper being cut by guillotine Clean all sensors using an air duster Ensure all springs are in contact with conveyor belts with a light pressure Increase or decrease tension where necessary by adjusting the M4 cap head screw for each spring assembly Check that program matches paper being cut by guillotine Check adjustment of side guides is not too tight Clean all sensors using an air duster Ensure all springs are in con tact with conveyor belts with a light pressure Increase ten sion where necessary by tightening the M4 cap head screw for each spring assembly Check that program matches paper being cut by guillotine Clean the S O L HP1 and HP2 sensors using an air duster Check spring pressure under each spring Engineer action if fault persists Check there are no material catch points related to the documents being processed Ensure all springs are in contact with conveyor belts with a light pressure Check the motor drive belt a Check by hand that the load o
6. Check all connections and settings are correct See AIMS and or IMOS error log file for more details If fault persists contact NTLIPSS Check all connections and settings are correct See AIMS and or IMOS error log file for more details If fault persists contact NTLIPSS Operator action if fault persists Contact a supervisor or the IT department for support Contact a supervisor or the IT department for support Contact a supervisor or the IT department for support Contact a supervisor or the IT department for support Contact a supervisor or the IT department for support Contact a supervisor or the IT department for support Engineer action if fault persists Test network and server status If network or server status is at fault contact your IT department for support Test network and server status If network or server status is at fault contact your IT department for support Test network and server status If network or server status is at fault contact your IT department for support Test network and server status If network or server status is at fault contact your IT department for support Test network and server status If network or server status is at fault contact your IT department for support Test network and server status If network or server status is at fault contact your IT department for support Page 80 Error Code 1042 1043 1044 1051 1052 Error Message Watchdog Not Receiv
7. Clear jam Press Start to continue Clear jam Press Start to continue Clear jam Press Start to continue Clear jam Press Start to continue Operator action if fault persists Ensure that all documents and damaged material is removed from the output divert units Press start to continue Ensure that all material is removed from the divert unit Ensure that the roller carrier is correctly locked in place Clean sensors with an air duster Ensure that the roller carrier is correctly locked in place Clean sensors with an air duster Ensure that the roller carrier is correctly locked in place Clean sensors with an air duster Ensure all material is removed from divert unit Ensure that the roller carrier is correctly locked in place Clean sensors with an air duster Ensure all material is removed from divert unit Ensure that the roller carrier is correctly locked in place Clean sensors with an air duster Ensure all material is removed from divert unit Ensure that the roller carrier is correctly locked in place Clean sensors with an air duster Ensure program is correct for envelope size being used Clean divert sensor on angled slope using an air duster Ensure divert conveyor is clear of material directly below the diverter Engineer action if fault persists a Check that the drive train from the motor is free running by rotating the motor shaft by hand and that all belts are properly on pulleys b Ru
8. Document failed to arrive at flatbed feeder exit Document jam at flatbed feeder exit Document lost in flatbed feeder Possible cor rupt group at sheet divert 1 Possible cor rupt group at sheet divert 2 Recovery Information Complete static align ment test then remove label and continue Documents have overrun the sensor or been removed Check for missing damaged documents before continuing A filled envelope has overrun the sensor or been removed Check for missing damaged documents before continuing Remove document from flatbed feeder Remove document from flatbed feeder Remove document which may have over run a sensor Remove group s at sheet divert 1 Remove group s at sheet divert 2 Operator action if fault persists Complete static alignment test then remove label and con tinue Clean sensors with an air duster Clean sensors with an air duster Check for paper traps for the particular paper being used Ensure that all material has been removed from the unit Clean belts and rollers Clean sensors with an air duster Ensure carrier assembly is latched in position Clean belts and rollers Clean sensors with an air duster Ensure carrier assembly is latched in position Clean belts and rollers Remove group s at sheet divert 1 Remove group s at sheet divert 2 Engineer action if fault persists Complete static alignment test then remove label and c
9. Unplug the power supply from the bus bar apply power to the power supply and use a meter to test the 36V rail Check power distribution sensor leads are correctly located Check LEDs are lit Check bus bar fuses Unplug the power supply from the bus bar apply power to the power supply and use a meter to test the 36V and 8V rail Check power distribution sensor leads are correctly located Check LEDs are lit Check bus bar fuses Page 57 Error Code 403 404 405 406 407 408 Error Message Envelope jam at printer exit Wrong Envelope size Detected by the Printer Change of Envelope size Detected Envelope Throat Depth has Changed Printer Cover Open Unexpected Envelope at Envelope Printer Recovery Information Remove envelopes from DEP Meter Correct any errors on the DEP Meter Press run to continue Please check the envelope size is programmed correctly in the Flexmail project If fault persists call Technical Support Check all envelopes from the vertical stacker conveyor have been removed Press start to run the selected job Check adjust the throat setting for the fingers on the side of the kicker assembly to X mm before running the job Please close all Printer covers and check the emergency stop is off Envelope has No Print Data Please remove all envelopes from the printer Then check settings before Pressing start to continue Operator action if fault pe
10. 218 219 220 221 Error Message Cannot Autoend First Of Group Job Bad Label length detected Document jam at Single Online hold point 2 Unexpected document at Single Online hold point 2 Document failed to arrive at Single Online hold point 2 Document lost at S O L HP2 Output Divert Hybrid motor stalled Recovery Information Remove all documents from unit or press Autoend button to force group as complete Remove Group from Shuttle Bed press Start to continue Remove all documents from Single Online Unit Check spring tensions Press Start to continue Remove all documents from Single Online Unit Check spring tensions Press Start to continue Remove all documents from Single Online Unit Check spring tensions Press Start to continue Remove documents from S O L and retry Remove all documents from Single Online Press Start to continue Operator action if fault persists See Recovery Information Ensure number of characters in label is set correctly Ensure data logging parameters are correct If variable length labels are being used different number of characters in each label switch security check to none Check adjustment of side guides is not too tight Clean all sensors using an air duster Ensure all springs are in contact with conveyor belts with a light pressure Increase tension where necessary by tightening the M4 cap head
11. Carefully clean the scanner lenses ask Technical Support for help in doing this if required Ensure that the franker is running and that it is clear of any damaged stationery See Recovery Information Check that all feeders are correctly loaded with material Clear the machine of paper and press Clear and Reset Engineer action if fault persists Before suspecting the machine ensure that the program being used is correct for the material being processed and that the marks match those of the calibration sheet Also ensure that the material is within the company specification Re calibrate the scanner and check performance If bad sequence is still returned a Go to Engineer test mode and check the static performance of the scanner against the calibration sheet b Check that the tacho is working correctly by moving the OMR conveyor belts and watching the light on the OMR board go on and off approximately 1 flash every 2mm c Check that the OMR conveyor belts are driving correctly and that the drive collars are locked securely to the shaft Before suspecting the machine ensure that the program being used is correct for the material being processed and that the marks match those of the calibration sheet Also ensure that the material is within the company specification Re calibrate the scanner and check performance If bad sequence is still returned a Go to Engineer test mode and check the static performance of the scanne
12. Check functionality of scanner in test mode b Check functionality of tacho and trigger for OMR using the lights on the OMR Barcode PCB c Ensure OMR Barcode conveyor belts are locked to the drive shafts and driving without slip Ensure that the feeder on line unit side guides are sufficiently tight to control paper within 1 to 2mm a Check functionality of scanner in test mode b Check functionality of tacho and trigger for OMR using the lights on the OMR Barcode PCB c Ensure OMR Barcode conveyor belts are locked to the drive shafts and driving without slip Ensure that the feeder on line unit side guides are sufficiently tight to control paper within 1 to 2mm a Check functionality of scanner in test mode b Check functionality of tacho and trigger for OMR using the lights on the OMR Barcode PCB c Ensure OMR Barcode conveyor belts are locked to the drive shafts and driving without slip Ensure that the feeder on line unit side guides are sufficiently tight to control paper within 1 to 2mm Page 47 Error Code 256 258 259 260 261 262 Error Message Reader Con figuration or Communica tions Error Reader Calibration has Failed Reader no reply No read group in Collate Pocket No read group in Divert 1 No read group in Divert 2 Recovery Information Reader has failed to respond correctly Enter Reader Setup Screen to re configure Check all connections and the configuration i
13. Ensure that the OMR transport belts are driving correctly and that the adjustable collars are securely clamped to the drive shafts f Check SOL solenoids are working correctly Check value of sensors clear and blocked in Engineer mode Re calibrate if necessary Check exit brake is work ing correctly Group size is too large so the group has been diverted Either change the action for too many forms or change the max fold settings ensure the max group size is in spec Group size is too large so the group has been diverted Either change the action for too many forms or change the max fold settings ensure the max group size is in spec a Check the value of the hi cap exit sensor b Check that all the clutches are freely rotating and not binding on c Check that all the hi cap brakes are working correctly d Check all the hi cap roller clutches are free running and not binding if fitted Page 55 Error Code 340 341 342 343 344 390 391 392 393 394 Error Message Unexpected document at output RX4 port error CAN Fault detected on PC Data logging message not found in buffer E D M Invalid repeat request General Cutter Error 1 General Cutter Error 2 General Cutter Error 3 Cutter Offline Sensors out of Range Recovery Information Capture a trace manually Record the last 5 envelopes to leave the machine Send ALL this to the company for Analysis Check all
14. OMR conveyor belts are driving correctly and that the drive collars are locked securely to the shaft a Check the shuttle bed sensor value blocked and clear note that this sensor is forced to a 13mA emitter current and should have a pot value of zero b Check the track top and bottom sensor values clear and blocked c Check the operation of the shuttle stepper d Check to ensure that shuttle belts are not too loose This is a function of stationery and programming This is a function of stationery and programming Page 38 Error Code 198 199 200 206 207 208 Error Message OMR mismatch in Divert Bin 2 OMR mismatch in Folder Omr Track depth mm requested for unit d is d and over limit of Yod Document jam at S O L exit Unexpected document at S O L exit Document failed to arrive at S O L Recovery Information Remove documents from Divert Bin 1 and manually correct Remove document from Folder OMR and manually correct Check configuration Remove documents from S O L exit Remove documents from S O L exit Remove documents from S O L unit Operator action if fault persists Using the touch screen touch the area of track where the mismatch has occurred Find which documents are out of place and remove further documents until matching is achieved You can remove one document at a time and let the machine cycle once until the next mismatch Keep doing this until the m
15. are correct contact technical support for help if you are not sure b Increase the level of shielding in document settings if it was 70 for example increase it to 80 c Increase the separator gap in Document If the paper appears to not be damaged or there is no form at the feed hold point then using an air duster clean the sensors in the feeder Ensure that the pivoting plate holding the 4 feed wheels is securely latched down the 2 latch knobs should be located in posts in the chassis Engineer action if fault persists Re set the LVDT device and PCB potentiometers using the installation instructions Consult the DS 200 technical documentation for details of the displayed fault Before checking the machine functionality ensure that the program settings for the material being used are correct a Check that feed wheels rotate and try to drive paper from hopper If feed wheels do not rotate then check clutch is functioning from engineer screens b If clutch is functioning but feed wheels are intermittent then check condition of 48 tooth final drive gear item 56 section 4c 1 c Lower the vane item 15 section 4c 1 request a feed and ensure that the conveyor drives strongly forward If not then remove conveyor and check fixing and condition of conveyor drive gears item 5n section 4c 1 d Check condition of feed tyres If worn then replace If not worn then consider use of alternative hi grip feed tyres see produc
16. b Check that all the clutches are freely rotating and not binding on c Check that all the hi cap brakes are working correctly d Check all the hi cap roller clutches are free running and not binding Contact Technical Support a Check the opener entry opener flap and conveyor HP1 sensor values clear and blocked b Check that the drives are consistent and that none of the rollers and belts are worn beyond use a Check the opener entry opener flap and conveyor HP1 sensor values clear and blocked b Check that the drives are consistent and that none of the rollers and belts are worn beyond use c Check that the hold point 1 stop rises and falls freely and that the solenoid is operating correctly a Check the hi cap overrun sensor blocked and clear b Look at the customers stationery and see if it is excessively distorted Advise accordingly c If possible raise the bracket holding the hi cap overrun sensor item 16 section 4c 9 using M4 washers Do not overdo this Page 25 Error Code 138 139 140 141 142 Error Message Unexpected document from upstream unit Wetter tank overflow Bad fold Folder open Document lost from Collate Hold point 1 Recovery Information Upstream unit Insert Track sensor may be out of calibration Check water level in wetter tank Remove document from Shuttle Bed and press Start If fault persists try reducing the speed Ensure folder is fully home
17. Check paper loaded Check brush is in down position Clear cutter fault NOT USED Remove forms at shuttle Remove envelopes from Frankers and env divert units NOT USED Remove all jammed envelopes from Out put Area Press Start to continue Remove all envelopes from the Output Area Check all devices are ready to continue Either refill feeder or remove incomplete group to allow au toend If FOG press autoend to complete Either refill feeder or remove incomplete group to allow au toend If FOG press autoend to complete Reset unit Autoend clear machine and restart Operator action if fault persists Check brushes are not too tight Check speed of job is not too high for perforation type Check web calmer is correctly positioned NOT USED Check the settings for max at shuttle is larger than the max pack size or divert oversized groups Ensure that the franker is running and that it is clear of any damaged stationery NOT USED Check job settings are correct for the envelope Check printer is set to correct envelope thickness Check franker interface tapes are pushing envelopes against transport rollers Reduce the machine speed The prime feed station is empty before the group is com plete Remove incomplete group and press autoend or re load hopper to continue The prime feed station is empty before the group is com plete Remove incomplete group and press autoend or re load hopper
18. Check solenoid adjustments are correct to provide sufficient lift to allow envelope cleanly into divert e Check divert conveyor pulses correctly and that conveyor belts do not slip Page 43 Error Code 234 235 236 Error Message Envelope failed to arrive at Output Divert 3 Divert Envelope jam at Output Divert 1 Divert Envelope jam at Output Divert 2 Divert Recovery Information Clear jam Press Start to continue Clear jam Press Start to continue Clear jam Press Start to continue Operator action if fault persists Ensure divert conveyor is clear of material directly below the diverter or if a mail bag is fitted ensure bin bag is not full or that mail bag is not restricting the free fall of the envelope Ensure program is correct for envelope size being used Clean divert sensor on angled slope using an air duster Ensure divert conveyor is clear of material directly below the diverter or if a mail bag is fitted ensure bin bag is not full or that mail bag is not restricting the free fall of the envelope Ensure program is correct for envelope size being used Clean divert sensor on angled slope using an air duster Ensure divert conveyor is clear of material directly below the diverter or if a mail bag is fitted ensure bin bag is not full or that mail bag is not restricting the free fall of the envelope Engineer action if fault persists Ensure hardware configuration is correct i e
19. Check the setup of the FFI Ensure that all cables are correctly connected and secured in place Check to see if the FFI is still powered and ready to operate Ensure that all cables are correctly connected and secured in place Check to see if the FFI is still powered and ready to operate Ensure that all cables are correctly connected and secured in place Check to see if the FFI is still powered and ready to operate Ensure that all cables are correctly connected and secured in place Check setup and readiness of FFI Engineer action if fault persists Check the operation of the collate stepper belts Check the operation of the pocket stepper belts Check sensors are working correctly N A Check the readiness of the FFI Check external and internal connections Check external and internal connections Check external and internal connections Check external and internal connections N A Page 76 Error Code 773 7174 175 997 998 999 1000 1001 1002 Error Message FFI Mailer Covers Open NO Matching Job Found Tandem Mode Lost Debug Fault Serial Port Debug Fault Cutter Bad Read Debug Fault Not used NACK Error Error Timeout Recovery Information Close covers and press start to continue Tandem mode requires the job names to be common Please check all settings are correct Check all settings are correct before trying again Use for debug only Use for debug only
20. Code 69 70 71 72 80 Error Message Document jam at collator eject Collate stepper failed to index Document Lost From Collate Pocket Collate Eject Document Lost Insert track stepper has stalled Recovery Information Slide collator back and remove documents from collator eject Press start to continue If documents have been removed and fault still remains call Technical Support Remove All docs from the Collate pocket Press Run to Con tinue Remove All docs from the Collate eject Press Run to Con tinue Remove documents from insert track as well as upstream and downstream transfers Operator action if fault persists Ensure the collate conveyor and collate pocket side guides are correctly adjusted Ensure that the document is correct for the job configuration Clean the eject sensor using an air duster Check that there are no obstructions in the collate pocket Check configuration and document details are correct Autoend and re calibrate sensors Check configuration and document details are correct Autoend and re calibrate sensors Check that there are no obstructions to the insert track path Check that the track belts are not damaged and that all the pawls are in place Check that the shuttle belts are not obstructing the insert track belts Engineer action if fault persists a Check the free running of the needle bearings on the bottom edge of the collate guide ext
21. Cutter emergency stop button pressed Cutter in fault condition Cutter not responding to serial comms Cutter tractor TR1 sensor clear Cutter tractor TR2 sensor clear Cutter paper switch TR1 clear Recovery Information Check re load paper in Cutter Close Cutter Cover Reset Cutter emergency stop Clear Cutter error Press Start to continue Check connections to cutter Press Start to operate in Parallel mode Clear paper and reload Clear cutter jam and single cycle paper to blade Check cutter in sync before continuing Clear paper and reload Clear cutter jam and single cycle paper to blade Check cutter in sync before continuing Check paper loaded Check brush is in down position Clear cutter fault Operator action if fault persists Ensure cutter tractors and trimmers are correctly set and cut paper is central to machine Clean cutter sensor with an air duster Ensure both sets of side guides on the on line interface are not too tight Ensure that all waste material is removed from around the trimmers and drive out rollers Ensure cover is closed Ensure the button is not being accidentally touched or interfered with Ensure cutter fault is cleared Press clear then single to bring the paper to the blade Ensure the cutter is not in a fault condition and ready to feed Also check the emergency stop button is not pressed Check that there is no pap
22. Engineer action if fault persists Test network and server status If network or server status is at fault contact your IT department for support Test network and server status If network or server status is at fault contact your IT department for support Test network and server status If network or server status is at fault contact your IT department for support Page 83
23. Remove documents in collator and retry Operator action if fault persists Check that all the shuttles are correctly down in position Ensure that the wetter tank is correctly located in position Remove the tank and empty it back into the main bottle Check that the material being used is correct for the job configuration Clean the fold rollers with roller cleaning fluid Clean the folder output rollers with a clean cloth and clean water Reduce the speed Unlatch the fold plate 1 3 move the fold plates up by hand then re latch it Clean the collate HP1 and HP2 sensors using an air duster Engineer action if fault persists a Check that the insert track top insert track bottom and insert track advanced for the station concerned and the up stream and downstream stations are correct both blocked and clear b Check that the solenoid stops are functioning correctly Before looking for machine faults first ensure that the customer is using sealing fluid If not then advise the customer of the accelerated wear and damage that can be caused by impurities in tap water Empty the tank then a Short out the terminals of the wetter tank level sensor and ensure the wetter tank empty message goes and the pump stops b If the sensing is correct check the free movement of the overflow magnet round magnet in a float If the folder is reporting bad folds falsely then a Check that the folder exit rollers item 29 section 4c 5 are grip
24. Values should be in the range 350 to 600 If they are outside of this range either the emitter or receiver may be faulty Advise the customer that their stationery contains repeated Piece IDs Check the functionality of the wheel sensor Ensure the lat est wheel sensor is fitted TB1530 203 Page 63 Error Code 495 496 497 498 499 500 501 Error Message Data Error Detected No J Messag es Received from PC TQM not ready TQM no reply TQM fault Vertical Stacker Input Failed to Index Vertical Stacker Input Stepper Stall Recovery Information Please remove all envelopes from the VS input area as well as the last envelope in the VS wheel Press Run to continue Last Envelope Proc essed had no TQM data Check Se quence TQM status is not ready Check TQM for more information Failed to establish communications with TQM TQM in fault condition Check TQM for fault information Remove Envelopes on the input and retry If fault persists call Technical Support Remove filled Envelope Press Start to continue Operator action if fault persists Ensure that you are correctly removing documents from the VS in the event of a crash in the VS Ensure that the wheel sensor is operating correctly and is not fouled by a paper blockage Check all serial cables and serial comm port settings TQM is in a fault condition and not ready to accept the next filled envelope Fix th
25. a divert conveyor is fitted to the divert unit a ensure that the divert backstop setting is not too tight approximately 2mm float on envelope width use twiddle screen to adjust if necessary b Ensure back stop is adjusting to the same position every time c Check value of divert sensor clear and blocked d Check solenoid adjustments are correct to provide sufficient lift to allow envelope cleanly into divert e Check divert conveyor pulses correctly and that conveyor belts do not slip a Ensure that the divert backstop setting is not too tight approximately 2mm float on envelope width with a conveyor or 12mm on envelope width with a mail bag use twiddle screen to adjust if necessary b Ensure back stop is adjusting to the same position every time c Check value of divert sensor clear and blocked d Check solenoid adjustments are correct to provide sufficient lift to allow envelope cleanly into divert e Check divert conveyor pulses correctly and that conveyor belts do not slip f If a mail bag is fitted ensure that the bag does not restrict free fall of the envelope note that for a mail bag you can increase the back stop setting by up to 15mm above the nominal setting as the accuracy is far less important than for a divert conveyor a Ensure that the divert backstop setting is not too tight approximately 2mm float on envelope width with a conveyor or 12mm on envelope width with a mail bag use twiddle screen to adj
26. are consistently in the same place on consecutive pages Check that the print quality is OK and that no marks are partially printed Check the pitch has not been changed relative to the calibration sheet Carefully clean the scanner lenses ask Technical Support for help in doing this if required Engineer action if fault persists Before suspecting the machine ensure that the program being used is correct for the material being processed and that the marks match those of the calibration sheet Also ensure that the material is within the company specification Re calibrate the scanner and check performance If bad read is still returned a Go to Engineer test mode and check the static performance of the scanner against the calibration sheet b Check that the tacho is working correctly by moving the OMR conveyor belts and watching the light on the OMR board go on and off approximately 1 flash every 2mm d Check that the OMR conveyor belts are driving correctly and that the drive collars are locked securely to the shaft Before suspecting the machine ensure that the program being used is correct for the material being processed and that the marks match those of the calibration sheet Also ensure that the material is within the company specification Re calibrate the scanner and check performance If bad read is still returned a Go to Engineer test mode and check the static performance of the scanner against the calibration sheet b Che
27. c The drive shaft rotates freely in the slide shaft and the brass bush in the side of the fold plate d The motor rotates freely when the fold plate is removed from the machine Check conveyor full switch is working correctly Check the serial connection and the serial comm port settings Page 66 Error Code 518 519 520 521 522 524 525 Error Message Vertical Stacker Not Received Status from Unit 0 Vertical Stacker No Reply Vertical Stacker Not Ready Forms Doc Data Records at the Cutter 2 Forms 2 Doc Data Records at SOL HP2 2 Forms 2 Doc Data Records at Col HP1 2 Forms 2 Doc Data Records at Col HP2 Recovery Information Press OK and then Run to Continue IF fault persists Power Cycle the Vertical Stacker and then reset unit Press OK and then Run to Continue IF fault persists Power Cycle the Vertical Stacker and then reset unit 0 Reset Vertical Stacker and press clear and restart to continue Remove documents from the unit and continue Check Document grouping is correct Remove documents from the unit and continue Check Document grouping is correct Remove documents from the unit and continue Check Document grouping is correct Remove documents from the unit and continue Check Document grouping is correct Operator action if fault persists Re power the vertical stacker Re power the vertical stacker Re power the vertical stack
28. correct operating condition If necessary power the printer off and re boot Use printer instructions to ensure printer is in correct operating condition If necessary power the printer off and re boot Ensure the inserter is in the correct operating condition Use the IJ 15K WJ Pro instructions to ensure the meter is in the correct operating condition If necessary power the meter off and re boot Use the IJ 15K W4J Pro instructions to ensure the meter is in the correct operating condition Use the IJ 15K WJ Pro instructions to ensure the meter is in the correct operating condition Engineer action if fault persists Re power the printer close the Flexmail application and restart Test using standard database and printer jobs supplied by NTL Re power the printer close the Flexmail application and restart Re power the printer Re power the printer close the Flexmail application and restart Use the IJ 15K WJ Pro instructions to ensure the meter is in the correct operating condition If necessary power the meter off and re boot Use the IJ 15K W4J Pro instructions to ensure the meter is in the correct operating condition Use the IJ 15K W4J Pro instructions to ensure the meter is in the correct operating condition Page 60 Error Code 423 424 425 426 427 428 429 Error Message Franker Error WJPro Emergency Stop WJPro Head Clean Requested No Acknowledge Message Received
29. correct operating condition If necessary power the meter off and re boot Use the IJ 15K WJ Pro instructions to ensure the meter is in the correct operating condition If necessary power the meter off and re boot Use the IJ 15K WJ Pro instructions to ensure the meter is in the correct operating condition If necessary power the meter off and re boot Engineer action if fault persists Use the IJ 15K WJ Pro instructions to ensure the meter is in the correct operating condition If necessary power the meter off and re boot Use the IJ 15K WJ Pro instructions to ensure the meter is in the correct operating condition If necessary power the meter off and re boot Use the IJ 15K WJ Pro instructions to ensure the meter is in the correct operating condition If necessary power the meter off and re boot Check all serial cables and serial comm port settings Check all serial cables and serial comm port settings Check all serial cables and serial comm port settings Check all serial cables and serial comm port settings Page 61 Error Code 430 431 432 434 435 436 437 438 Error Message Warning Message Received from WJPro lJ 15K Communica tion Error with W4JPro J 15K WJPro lJ 15K Not Ready Processing was stopped due to the loop switch for the cutter detecting an error Loop Switch for Cutter is Clear Prime Stop Button has been Activated Sequence Error Detected on Cutter C
30. d That the motor rotates freely when the fold plate is unlatched a Remove the backstop guide item 15 section 4a 14 replace the guide into its correct position ensuring that the leadscrew is straight If the leadscrew is being forced out of alignment then it will eventually bind up If the leadscrew is being distorted carefully bend the backstop guide item 15 section 4a 14 until the leadscrew item 13 section 4a 15 is straight and the bracket slides freely into its correct position b Check the backstop sensor blocked and clear a Check that the separator motor runs up and down in engineer mode b Re calibrate separator to 80gsm setting c Check separator motor clock sensor blocked and clear Page 20 Error Code 108 109 110 111 112 Error Message Track guide motor has stalled Collate motor has stalled Closer motor has stalled Turnover back stop stalled A document has jammed on the insert track Recovery Information If fault persists call Technical Support If fault persists call Technical Support Ensure all documents are removed from closer If fault continues call Technical Support If fault continues call Technical Support Remove documents from Insert Track as well as upstream and down stream transfers Press start to continue Operator action if fault persists Ensure all paper is removed from the insert track Check that all paper is removed from the collat
31. drive shafts and driving without slip Ensure that the feeder on line unit side guides are sufficiently tight to control paper within 1 to 2mm a Check functionality of scanner in test mode b Check functionality of tacho and trigger for OMR using the lights on the OMR Barcode PCB c Ensure OMR Barcode conveyor belts are locked to the drive shafts and driving without slip Ensure that the feeder on line unit side guides are sufficiently tight to control paper within 1 to 2mm a Check functionality of scanner in test mode b Check functionality of tacho and trigger for OMR using the lights on the OMR Barcode PCB c Ensure OMR Barcode conveyor belts are locked to the drive shafts and driving without slip Ensure that the feeder on line unit side guides are sufficiently tight to control paper within 1 to 2mm Re calibrate reader on latest printed material a Check functionality of scanner in test mode b Check functionality of tacho and trigger for OMR using the lights on the OMR Barcode PCB c Ensure OMR Barcode conveyor belts are locked to the drive shafts and driving without slip Ensure that the feeder on line unit side guides are sufficiently tight to control paper within 1 to 2mm Barcode character has been incorrectly read check barcode setup is correct and printing is clear Page 49 Error Code 270 271 272 273 274 275 276 277 Error Message Cutter paper fault Cutter cover open
32. failed to arrive at collator input 63 Document jam at collator input Recovery Information Open Hi cap feeder top cover and remove document Press start to continue Open Hi cap feeder and OMR Barcode unit covers Remove document in OMR Barcode unit Press start to continue Open collator cover and top conveyor Remove document at input to top conveyor Press start to continue Open collator cover and top conveyor Remove document at feeder end of top conveyor Press start to continue Operator action if fault persists Check that the hi cap pressure roller assembly is properly latched down Clean all hi cap feed and transport rollers with clean water and a clean cloth Check that the hi cap pressure roller assembly is properly latched down Clean all hi cap feed and transport rollers with clean water and a clean cloth Check that the hi cap pressure roller assembly is properly latched down Clean all hi cap feed and transport rollers with clean water and a clean cloth Clean all hi cap feed and transport rollers with clean water and a clean cloth Check that there are no obstructions in the OMR Barcode unit Ensure the collate conveyor and collate pocket side guides are correctly adjusted Engineer action if fault persists a Check the 2 feed clutches are driving correctly and that they are not slipping b Check that the hi cap brakes are not binding c Check that the roller clutches in all the transport r
33. from Shuttle Bed Press start to continue Remove envelope from insert area Press start to continue Remove filled envelope from end of turnover Press start to continue Remove filled envelope and document from insert platform Press start to continue Operator action if fault persists Check that there are no obstructions to the shuttle stepper Check that the shuttle belts are not damaged and that all the pawls are in place Check that the insert track stepper belts are not obstructing the shuttle belts Check to ensure that the shuttle adjustable tapes are not too strong causing the document on the shuttle bed to hold back the belts Check that the outer fingers are approximately 9mm in from the edge of the envelope Check that the outer fingers enter the envelope just before the inner and middle fingers Use the adjusting knob on the top of the kicker assembly to move the middle fingers further in or out of the envelope the middle fingers should be just inside the throat when fully in Check that there are no obstructions to the turnover eject stepper Check that the eject belt is not damaged and that all the pawls are in place Check that there are no obstructions to the kicker stepper Check that the kicker belts are not damaged and that all the pawls are in place Check that the handover pawled belts are not obstructing the kicker belts Engineer action if fault persists a Check condition of pawled belts b Chec
34. mechanism which the motor has to drive b Disconnect the motor from the mechanism so that it operates without load and check functionality c Check that the connectors are securely in place on the module hybrid PCB and that none of the wires are loose or broken d Check that there is no local heating of the power connector 3 pin connector and that there are no signs of burning around the connector a Check by hand that the load on the motor is normal and that there is no binding in the mechanism which the motor has to drive b Disconnect the motor from the mechanism so that it operates without load and check functionality c Check that the connectors are securely in place on the module hybrid PCB and that none of the wires are loose or broken d Check that there is no local heating of the power connector 3 pin connector and that there are no signs of burning around the connector Page 35 Error Code 184 185 186 187 188 Error Message Form failed to arrive at Folder OMR Form jammed in Folder OMR Unexpected form in Folder OMR Form jammed in Folder OMR Folder OMR not latched home Recovery Information Remove forms from unit Re load and press start to continue Remove forms from unit Re load and press start to continue Remove forms from unit Re load and press start to continue Remove forms from unit Re load and press start to continue Push Folder OMR until fully home Ope
35. mode as the DC motors are not under any control other than that of the engineer b Check the mask motor clock blocked and clear Before looking for machine faults first ensure that the customer is using sealing fluid If not then advise the customer of the accelerated wear and damage that can be caused by impurities in tap water a Short out the terminals of the wetter tank level sensor and ensure the message disappears b If the sensing is correct but no fluid arrives at the header tank check the pump is operating and drawing water c Check that there are no obstructions in the pipe a Check that the tray can lift and fall freely when disconnected from the motor b Check that the motor runs when disconnected from the lifting mechanism c Check that both disc sensors are correct both blocked and clear a Check that the trolley is the right one for the unit under test and that it is correctly aligned using the alignment holes in the chassis and the trolley side walls b Check that the cover magnet is in place and not damaged c Test the read switch by using a test magnet against it and ensure the message disappears a Check that the feed clutch operates correctly and that the feed wheels try to feed paper a Check that the doubles sensor will return sensible values when calibrated on 80gsm paper b Check that the material being used does not present a solid black print to the doubles detector If so then move the sensor acros
36. next tractor to fire before proceeding Check the program is correct Engineer action if fault persists Check all serial cables and serial comm port settings Check all serial cables and serial comm port settings Check all connections between the DS 1XXX and the meter Test the loop switch functionality Test the loop switch functionality Test the switch action is correct and that the microswitch opens and closes correctly Test the circuit for open and closed conditions Page 62 Error Code 439 440 441 442 443 444 494 Error Message VOIDS at Shuttle Document Not Arrived at Itrack Sub Group Removed by Operator Wrong Job Number Detected Too Many Successive Thick Doubles Detected Too Many Successive Duplicate Mail Pieces Detected Vertical Stacker Data Error Detected Capture a trace from the VS and the inserter and send to NTLIPSS Recovery Information Please Remove ALL documents from the shuttle and Press Go to continue Please Remove ALL documents from the Itack Press Go to continue Please Remove the document from the Itack home position only Press Go to continue Please Remove the document from unit Please Remove any documents in the collate and check all settings stationary before continuing Press Go to continue Please Remove any documents in the collate and check all settings stationary before continuing Press Go to continue C
37. running freely c check that the pressure rollers in the divert assembly are running freely and that the white springs are in place on the front pressure shaft the one with the rubber tyres d Check the solenoid fires correctly and that the stop drops below the conveyor bed by at least 1mm Page 8 Error Code 33 34 35 36 37 Error Message An unopened envelope is on the conveyor Unopened envelope has not been fully ejected from eject area Unopened envelope has not been fully ejected from eject area Envelope not correctly positioned at insert platform The envelope at insert area has been damaged and has not ejected correctly Recovery Information Open Divert assembly and remove envelope from conveyor Press start to continue Open Divert assembly and remove envelope from reject rollers Press start to continue Open Divert assembly and remove envelope from reject rollers Press start to continue Remove partially fed envelope from insert platform or from under the insert plate Remove envelope with contents Also remove document on insert platform Press start to continue Operator action if fault persists Check to ensure that envelopes are not damaged before use and that the windows are securely gummed down Ensure side guides are correctly set and that envelopes are feeding squarely into the machine Always ensure that the divert assembly ope
38. shafts have not drifted Check that the turnover backstop motor runs backwards and forwards in engineer mode If the backstop motor is struggling to drive the turnover backstop then a Disassemble the backstop mechanism b Check that the slider moves freely up and down the slide shaft c Check that the drive shaft rotates freely in the slide shaft and the brass bush in the turnover chassis d Check that the motor rotates freely when not attached to the mechanism a Check condition of pawled belts b Check that motor pulley is securely locked to the motor shaft c Check the insert track index sensor blocked and clear d While still in Engineer stepper test add resistance to the pawls and watch the change in returned clocks This should give an indication of the strength of the stepper e Check that the idle pulleys item 25 section 4b 8 are in place and that both flanges are in place Page 21 Error Code 113 114 115 116 117 118 119 Error Message Shuttle cannot resync Insert track cannot resync Handover cannot resync Kickers cannot resync Turnover eject cannot resync Documents failed to arrive at insert area FlapDelayed Recovery Information Remove documents from Shuttle Bed Press start to continue Remove documents from Insert Track as well as upstream and downstream transfers Press start to continue Remove documents from Insert platform as well as unit 1 transf
39. slip c Check the functionality of the hp1 clutch and brake d Check the sensor values clear and blocked for the hi cap exit sensor e Ensure that the OMR transport belts are driving correctly and that the adjustable collars are securely clamped to the drive shafts f Check to ensure that there are enough guide brackets item 7 section 4c 26 and that they are guiding the paper over the chassis bridges Page 13 Error Code 64 65 66 67 68 Error Message Document failed to arrive at collator second hold point Document jam at collator second hold point Document failed to arrive in collator pocket Document jam in collate pocket Document failed to arrive at collator eject Recovery Information Open collator cover and top conveyor Remove document at feeder end of top conveyor Press start to continue Open collator cover and top conveyor Remove document at output end of top conveyor Press start to continue Open collator cover top conveyor and lower conveyor Remove documents Press start to continue Open collator cover top conveyor and lower conveyor Remove documents Press start to continue Open collator cover top conveyor and lower conveyor Remove documents Press start to continue Operator action if fault persists Check that there are no obstructions in the OMR Barcode unit Check there are no obstructions in the collate conveyor section Clean the collate co
40. that all material has been removed from the collate Unlatch the collate and remove material from the gap between the collate and the divert unit Ensure that all material has been removed from the collate Unlatch the collate and remove material from the gap between the collate and the divert unit Open the divert lid and remove any material in the divert conveyor Clean all the divert sensors and the collate exit sensor with an air duster Engineer action if fault persists a Check by hand that the load on the motor is normal and that there is no binding in the mechanism which the motor has to drive b Disconnect the motor from the mechanism so that it operates without load and check functionality c Check that the connectors are securely in place on the module hybrid PCB and that none of the wires are loose or broken d Check that there is no local heating of the power connector 3 pin connector and that there are no signs of burning around the connector a Check by hand that the load on the motor is normal and that there is no binding in the mechanism which the motor has to drive b Disconnect the motor from the mechanism so that it operates without load and check functionality c Check that the connectors are securely in place on the module hybrid PCB and that none of the wires are loose or broken d Check that there is no local heating of the power connector 3 pin connector and that there are no signs of burning around
41. that envelopes are feeding squarely into the machine Always ensure that the divert assembly opened with the black handle is securely latched down Check to ensure that envelopes are not damaged before use and that the windows are securely gummed down Ensure side guides are correctly set and that envelopes are feeding squarely into the machine Always ensure that the divert assembly opened with the black handle is securely latched down Ensure that all paper has been removed from the unit Ensure that all paper has been removed from the unit Engineer action if fault persists a Check the HP1 sensor is correct clear and blocked b Check the drives to the conveyor are running freely c check that the pressure rollers in the divert assembly are running freely and that the white springs are in place on the front pressure shaft the one with the rubber tyres d Check the solenoid fires correctly and that the stop drops below the conveyor bed by at least 1mm a Check the HP1 sensor is correct clear and blocked b Check the drives to the conveyor are running freely c check that the pressure rollers in the divert assembly are running freely and that the white springs are in place on the front pressure shaft the one with the rubber tyres d Check the solenoid fires correctly and that the stop drops below the conveyor bed by at least 1mm a Check by hand that the load on the motor is normal and that there is no binding in the
42. the connector No action a Check the divert entry and collate exit sensor values blocked and clear b Check for paper traps for the particular paper being used a Check the divert entry and collate exit sensor values blocked and clear b Check for paper traps for the particular paper being used a Check the divert entry and collate exit sensor values blocked and clear b Check for paper traps for the particular paper being used c Check that the divert 1 solenoid functions correctly d Run the divert motor in engineer and activate the divert 1 solenoid by hand and by machine control In either case ensure the divert functions easily and that there is not excessive load imparted by the drive shaft against the movement of the divert solenoid e Check the functionality of the divert bin 1 sensor Page 29 Error Code 157 158 159 160 161 Error Message Document jam at Divert Bin 1 Document failed to arrive at Divert Bin2 Document jam at Divert Bin 2 Document jam at Divert Entry Document failed to arrive at Divert Exit Recovery Information Remove documents in Divert Bin 1 and retry If fault persists call Technical Support Remove documents in Divert Bin 2 and retry Remove jam and retry Remove jam and retry Operator action if fault persists Ensure that the divert bin side guides are not too tight for the stationery being processed Ensure you are not overfilling the divert
43. the shield setting if it was say 80 reduce it to 70 Don t decrease the shield setting too much or the feeder may not pick up correctly b If the shield setting does not resolve the problem return it to its original setting and reduce the separator gap If the fault still persists try the shield again with the reduced separator setting Clean all rollers of the feed assembly Make sure the document is loaded before the SOL HP 2 solenoid and is blocking the HP2 sensor Check side guides are not restricting the document Check the fold settings relative to the paper being used Check that the fold box 1 3 is securely located Check the fold settings relative to the paper being used Check that the fold box 1 3 is securely located Check the fold settings relative to the paper being used Check that the fold box 1 3 is securely located Engineer action if fault persists Check all operator program settings before looking for machine faults a Check that the pick up wheel roller clutches are freely rotating and not binding b Check that the shield is correctly indexing c Check 80gsm separator setting re calibrate if necessary d Check the feed brake is operating correctly Check the operation of the clutches and brakes in engineer Check for binding Upgrade to at least V5 02 firmware Check for correct springs on pressure assembly Hi cap to a folder requires springs G1026A in all locations Check SOL HP2 solenoid i
44. tings for this unit Reduce number to fewer than 50 Press Clear and Re start and try again Press Clear and Re start and try again Check marked groups s Check last groups s Is a page missing Operator action if fault persists Remove group s at shuttle If fault persists call Technical Support Clean all sensors using an air duster Clean all sensors using an air duster The document programmed for this unit is below the mini mum allowed Change document settings Remove some of the late diverts from the PICS late divert log as the max capacity of 50 labels has been exceeded Check late divert log ensure there are fewer than 50 labels Press Clear amp restart a try again Check late divert log for errors Press clear and re start to send the configuration to the machine If fault persists restart the application Be careful to return documents to correct positions if re moved Possibly caused by a no read Check the label is in the envelope window Investigate cause of missing page or bad read Engineer action if fault persists Remove group s at shuttle If fault persists call Technical Support Check HP1 amp feed exit sensors Check operation of feed clutch and brake in engineer Check for clutch binding on Check HP1 and HP2 sensors Check operation of HP1 clutch and brake in Engineer Check for HP1 clutch binding on See operator trouble shooting Also
45. to continue If fault persists call Technical Support Engineer action if fault persists Check web calmer is operating correctly and that distance between cutter and merger is correct NOT USED Check the settings for max at shuttle is larger than the max pack size or divert oversized groups a Check that envelopes leave the machine without the use of the franker B Check the values of the wetter closer exit sensor and the franker sensor clear and blocked NOT USED Check all transport systems are functioning correctly Check all drive and transport rollers are operating correctly and are free to rotate Ensure there are no obstructions to movement of the envelope through the output system Check print run to see if the end of group page is missing or check enough docs to complete fixed multiple group If FOG and run is complete autoend without removing docu ments then force autoend when prompted Check print run to see if the end of group page is missing Or check enough docs to complete fixed multiple group If FOG and run is complete autoend without removing docu ments then force autoend when prompted Check the machine is earthed properly Ensure all static elimination devices are in place and properly earthed Page 51 Error Code 291 300 301 302 303 304 310 311 Error Message Label under reader Document lost from sheet divert HP Document lost from turnover eject HP
46. units are powered If fault persists then capture a trace manually Send this to the company for Analysis Capture a trace manually Send this to NTL for Analysis Capture a trace manually Send this to NTL for Analysis Capture a trace manually Send this to NTL for Analysis Check Cutter for exact Fault Check Cutter for exact Fault Check Cutter for exact Fault Turn Cutter Online Press Autoend to Re Calibrate Sensors Operator action if fault persists If you leave the run screen then choose NO for abandon job or remaining docs will cause code 340 Remove all documents manually from the machine Press Clear and re start and Try again If Fault continues follow recovery information If fault persists call Technical Support Capture a trace manually Send this to NTL for Analysis Capture a trace manually Send this to NTL for Analysis Capture a trace manually Send this to NTL for Analysis NO SYNC MARK READ NO MIN NUMBER OF MARKS READ Go to the cutter run screen for error information Check power is ON and ensure all electrical connections are secure Check all sensors have been cleaned and re calibrated Engineer action if fault persists Possible CAN BUS Fault Upgrade to USB CAN CARD If fault persists call Technical Support Check all comms serial wiring and that the cable and units are earthed Check control PCB issue level is current Capture a trace manually Send this
47. AIMS requires the next FOG to be removed at the completion of the job run Remove Envelope from the Opener Hold Point HP1 Press start to continue Open Divert assembly and remove envelope from conveyor Press start to continue Open Divert assembly and remove envelope from conveyor Press start to continue Open Divert assembly and remove envelope from conveyor Press start to continue Operator action if fault persists This is a correct operating message If you do not want this message appearing at the end of a job then the job or material need to be changed Check HP is clear of envelopes Clean the sensor with an air duster if required Remove all envelopes from the enve lope path on unit 0 Check that the pivoting plate carrying the 4 rollers at the entry to the opener is securely latched down Using an air duster clean the opener entry and opener flap sensors Always ensure that the divert assembly opened with the black handle is securely latched down Check to ensure that envelopes are not damaged before use and that the windows are securely gummed down Ensure side guides are correctly set and that envelopes are feeding squarely into the machine Always ensure that the divert assembly opened with the black handle is securely latched down Check to ensure that envelopes are not damaged before use and that the windows are securely gummed down Ensure side guides are correctly set and t
48. Check condition of pawled belts b Check that motor pulley is securely locked to the motor shaft c Check the turnover eject index sensor blocked and clear and the turnover eject clock sensor blocked and clear d Run the stepper in Engineer screen and check the returned number of clocks forward and back These should be equal in both directions to within 2 clocks e While still in Engineer stepper test add resistance to the pawls and watch the change in returned clocks This should give an indication of the strength of the stepper a Check condition of pawled belts b Check that motor pulley is securely locked to the motor shaft b Check the kicker index sensor blocked and clear and the kicker clock sensor blocked and clear d Run the stepper in Engineer screen and check the returned number of clocks forward and back These should be equal in both directions to within 2 clocks e While still in Engineer stepper test add resistance to the pawls and watch the change in returned clocks This should give an indication of the strength of the stepper f Check that the kicker belt pawls are not hitting any part of the kicker assembly or the insert platform g Check that at the front end the kicker pawls are at least 2mm above the insert platform Page 18 Error Code 94 95 99 100 101 102 Error Message Handover stepper failed to index Collate Eject stepper failed to index Output Transfer Drive motor stal
49. Check that the hi cap pressure roller assembly is properly latched down Clean all hi cap feed and transport rollers with clean water and a clean cloth For an online systems check spring pressures on SOL check HP stops are oper ating correctly and not sticking Clean sensors with an air duster The settings for too many action or the settings for max fold are set incorrectly for the job that is being run Check max group size if running fixed multiple is less than the max fold The settings for too many action or the settings for max fold are set incorrectly for the job that is being run Check max group size if running fixed multiple is less than the max fold Check that the hi cap pressure assembly is securely latched down Clean all Hi Cap sensors with an air duster Clean all feed and transport wheels with a clean cloth and clean water For an online systems check spring pressures on SOL check HP stops are operating correctly and not sticking Engineer action if fault persists See operator trouble shooting Change the control mode for the conveyor errors or ink mark to one of the other options that does not stop the machine a Check the 2 feed clutches are driving correctly and that they are not slipping b Check that the hi cap brakes are not binding c Check that the roller clutches in all the trans port rollers are running freely d Check the sensor values clear and blocked for the hi cap exit sensor e
50. DS 1000 1200 Advanced Troubleshooting Guide For use by Operators and Engineers Select the required Error Code 1 7 Page 3 28 32 Page 8 60 63 Page 13 91 93 Page 18 120 126 Page 23 147 150 Page 28 171 174 Page 33 194 197 Page 38 230 233 Page 43 256 262 Page 48 312 322 Page 53 403 408 Page 58 8 11 Page 4 33 37 Page 9 64 68 Page 14 94 102 Page 19 127 131 Page 24 151 156 Page 29 175 179 Page 34 198 208 Page 39 234 236 Page 44 263 269 Page 49 323 332 Page 54 409 414 Page 59 12 17 Page 5 38 42 Page 10 69 80 Page 15 103 107 Page 20 132 137 Page 25 157 161 Page 30 180 183 Page 35 209 214 Page 40 237 242 Page 45 270 277 Page 50 333 338 Page 55 415 422 Page 60 18 22 Page 6 43 47 Page 11 81 85 Page 16 108 112 Page 21 138 142 Page 26 162 167 Page 31 184 188 Page 36 215 221 Page 41 243 249 Page 46 278 290 Page 51 340 394 Page 56 423 429 Page 61 23 27 Page 7 48 55 Page 12 86 90 Page 17 113 119 Page 22 143 146 Page 27 168 170 Page 32 189 193 Page 37 222 229 Page 42 250 255 Page 47 291 311 Page 52 395 402 Page 57 430 438 Page 62 Page 1 MAIN MENU DS 1000 1200 Advanced Troubleshooting Guide For use by Operators and Engineers Select the required Error Code
51. Piece ID on the Document in Sheet Divert Bin 1 Invalid Piece ID on the Document in Sheet Divert Bin 2 Piece ID Not Match Please Remove all the Documents from the SOL unit You Must Now Autoend this Job Collate Backstop Carriage has stalled Unexpected Envelope at the Flap Gripper Sensor Recovery Information Remove group from Divert 1 and manually correct Remove Documents from Divert 1 and manually correct Remove Documents from Divert 2 and manually correct Remove ALL documents from the collate unit and manually check correct Please Remove all the Documents from the SOL unit You Must Now Autoend this Job Remove any documents from the collate pocket Check for any obstructions Remove envelope and or inserts from the handover insert area Also check there are no envelopes at the Envelope HP2 Operator action if fault persists Check the material being processed is for the correct job run Also check with a supervisor that the job run has not been reprinted Check the material being processed is for the correct job run Also check with a supervisor that the job run has not been reprinted Check the material being processed is for the correct job run Also check with a supervisor that the job run has not been reprinted Check the material being processed is in the correct page sequence Check to ensure that you are running the correct job Chaeck to ensure you have not continued
52. Please see DS1XXX AIMS setup doc V5 or above in the inserter documentation directory C Program Files x86 Documentation Other Documentation ADF AIMS Engineer action if fault persists Ensure doubles is deselected and that the correct configuration for the envelope chosen is being used If it is then a Check the opener entry opener flap and envelope opener conveyor HP1 sensors clear and blocked values b Check that the opener extrusion rotates freely and that the return spring is in place Check the blocked and clear values of the HP sensor Check that the side guide motor runs backwards and forwards in engineer mode If mechanism is struggling to drive the assembly the dismantle and check for damage Check the leadscrew is not damaged Check the side guides are not bent distorted adjust if required Check the motor drives correctly when not attached to the mechanism NA Check that only printed marks are being detected not ghost set off or marks seen through the page Advise train the customer operator where to look to understand IMOS and AIMS settings Page 7 Error Code 28 29 30 31 32 Error Message FOG Document Needs to be Removed Envelope Side Guide Sync Blocked Envelope has not arrived at conveyor stop Envelope has not left conveyor hold point Envelope has not left conveyor hold point Recovery Information Autoending FOG documents with
53. Use for debug only Check all connections and settings are correct See AIMS and or IMOS error log file for more details If fault persists contact NTLIPSS Check all connections and settings are correct See AIMS and or IMOS error log file for more details If fault persists contact NTLIPSS Operator action if fault persists Check covers are correctly in place and closed Check the job setting are compatible between the FFI and the DS 1200 Check to see if the FFI is still powered and ready to operate Ensure that all cables are correctly connected and secured in place Contact a supervisor or the IT department for support Contact a supervisor or the IT department for support Engineer action if fault persists Check cover magnets are in good condition and operating correctly N A Check external and internal connections Test network and server status If network or server status is at fault contact your IT department for support Test network and server status If network or server status is at fault contact your IT department for support Page 77 Error Code 1003 1004 1005 1006 1021 Error Message Error CMD NOT sent correctly Cancelled by User Duplicate Mail Piece Cannot Connect To AIMS Possible TCP IP Error Data Received AIMS Error Recovery Information Check all connections and settings are correct See AIMS and or IMOS error log file for more details If fault persists
54. a Check by hand that the load on the motor is normal and that there is no binding in the mechanism which the motor has to drive b Disconnect the motor from the mechanism so that it operates without load and check functionality c Check that the connectors are securely in place on the module hybrid PCB and that none of the wires are loose or broken d Check that there is no local heating of the power connector 3 pin connector and that there are no signs of burning around the connector Page 28 Error Code 151 152 153 154 155 156 Error Message Diverter Motor failed to achieve speed Divert motor stall OMR Barcode ID Field Mismatch Document failed to arrive at Divert Entry Unexpected document at Divert Entry Document failed to arrive at Divert Bin1 Recovery Information Press Start to continue If fault persists call Technical Support If fault persists call Technical Support Check document order in stack Remove documents and retry Remove documents and retry If fault persists call Technical Support Operator action if fault persists Ensure that all paper has been removed from the unit Ensure that all paper has been removed from the unit Ensure the barcode program matches the stationery being processed Ensure that all material has been removed from the collate Unlatch the collate and remove material from the gap between the collate and the divert unit Ensure
55. achine brings the matching back together correctly Using the touch screen touch the area of track where the mismatch has occurred Find which documents are out of place and remove further documents until matching is achieved You can remove one document at a time and let the machine cycle once until the next mismatch Keep doing this until the machine brings the matching back together correctly Ensure that the configuration of the current job is correct Check adjustment of side guides is not too tight Clean all sensors using an Air Duster Ensure all springs are in contact with conveyor belts with a light pressure Increase tension where necessary by tightening the M4 cap head screw for each spring assembly Check that program matches paper being cut by guillotine Clean all sensors using an Air Duster Ensure all springs are in contact with conveyor belts with a light pressure Increase or decrease tension where necessary by adjusting the M4 cap head screw for each spring assembly Check that program matches paper being cut by guillotine Check adjustment of side guides is not too tight Clean all sensors using an Air Duster Ensure all springs are in contact with conveyor belts with a light pressure Increase tension where necessary by tightening the M4 cap head screw for each spring assembly Check that program matches paper being cut by guillotine Engineer action if fault persists This is a function of stationery and program
56. ag 3 Remove filled envelope from unit 0 Remove filled envelope from output divert unit 1 Remove filled envelope from output divert unit 2 Remove filled envelope from output divert unit 3 Operator action if fault persists Edit configuration output to modify the number of envelopes or weight of envelopes in a batch If not required then turn batch off in either the configuration screen or the output twiddle screen Edit configuration output to modify the number of envelopes or weight of envelopes in a batch If not required then turn batch off in either the configuration screen or the output twiddle screen Edit configuration output to modify the number of envelopes or weight of envelopes in a batch If not required then turn batch off in either the configuration screen or the output twiddle screen Clean area around exit sensor Check that the pressure chassis is correctly located to drive envelopes through the divert unit Check that the pressure chassis is correctly located to drive envelopes through the divert unit Check that the pressure chassis is correctly located to drive envelopes through the divert unit Engineer action if fault persists Advise customers of use of batch counting use of batch control modes etc Advise customers of use of batch counting use of batch control modes etc Advise customers of use of batch counting use of batch control modes etc
57. ak Achieve the best position to allow the machine to operate and call the Service Engineer to replace the magnet If the cover will not allow the machine to run under any conditions call the Service Engineer Contact IPSS for further advice Ensure that the pressure roller transport bracket is securely locked down Check to see that LVDT sensor is securely located and that the plunger is moving freely Ensure that the pressure roller transport bracket is securely locked down Check to see that LVDT sensor is securely located and that the plunger is moving freely Run the calibration process again ensuring that the LVDT plunger moves up and down freely Engineer action if fault persists Processor fault a Check alignment of cover magnets to reed switches b Check operation of reed switch by using a detached magnet If reed switch will not close then replace c Check performance of cover magnet should allow a minimum of 2mm before message appears If magnets are weak then replace them Contact IPSS for further advice Re set the LVDT device and PCB potentiometers using the installation instructions Re set the LVDT device and PCB potentiometers using the installation instructions Re set the LVDT device and PCB potentiometers using the installation instructions Page 3 Error Code 10 11 Error Message Too many successive thickness checker failures detected Card feeder in fault condition Feeder Em
58. and printer jobs supplied by NTL Page 59 Error Code 415 416 417 418 419 420 421 422 Error Message Unable to Run as Data in Envelope Printer Buffer Wrong Printer Job Selected Remove Envelopes From Printer Printer Purged Env Failure Purge Envelope Not Allowed WJPro Meter Requires Attention WJPro Ink Low WJPro Funds Low Recovery Information Manually Feed Blank Envelopes through the Printer Or press clear printer buffer on the run screen until the Print Heads Park and the Belts Stop Modify printer job name in configuration and or flexmail script Open the Vertical Stacker Cover and Remove all Envelopes Check Printer is On Line and Repeat Purge if Required Purge Envelope in a Job Run or Select Purge from the Printer Control Panel Attached meter requires the print heads to be cleaned Please Clean the Print heads then Press Go to continue Check the Ink Level of the Franker See Franker Instructions for Details Check the Funds Level of the Franker See Franker Operator action if fault persists Use printer instructions to ensure printer is in correct operating condition If necessary power the printer off and re boot Check job settings and print job reference Use printer instructions to ensure printer is in correct operating condition If necessary power the printer off and re boot Use printer instructions to ensure printer is in
59. ation Remove documents on Track and retry If fault persists call Technical Support Remove documents under Turnover and retry If fault persists call Technical Support Remove documents in Insert area and retry If fault persists call Technical Support Operator action if fault persists Check that there are no obstructions to the insert track path Check that the track belts are not damaged and that all the pawls are in place Check that the shuttle belts are not obstructing the insert track belts Check that there are no obstructions to the turnover eject stepper Check that the eject belt is not damaged and that all the pawls are in place Check that there are no obstructions to the kicker stepper Check that the kicker belts are not damaged and that all the pawls are in place Check that the handover pawled belts are not obstructing the kicker belts Engineer action if fault persists a Check condition of pawled belts b Check that motor pulley is securely locked to the motor shaft c Check the insert track index sensor blocked and clear and the insert track clock sensor blocked and clear d Run the stepper in Engineer screen and check the returned number of clocks forward and back These should be equal in both directions to within 2 clocks e While still in Engineer stepper test add resistance to the pawls and watch the change in returned clocks This should give an indication of the strength of the stepper a
60. ault persists Run a standard camera job to ensure the system operates correctly Check the operation of the FFPD divert solenoid and return spring Check the operation of the FFPD divert solenoid and return spring Check the operation of the FFPD divert solenoid and return spring Check the operation of the FFPD divert solenoid and return spring Check the operation of the collate stepper belts Check the operation of the collate stepper belts Check the operation of the pocket stepper belts Check sensors are working correctly Check the operation of the collate stepper belts Check the operation of the pocket stepper belts Check sensors are working correctly Check the operation of the collate stepper belts Check the operation of the pocket stepper belts Check sensors are working correctly Check the operation of the collate stepper belts Check the operation of the pocket stepper belts Check sensors are working correctly Page 74 Error Code 758 759 760 761 762 763 764 Error Message FFPD Exit Conveyor Unexpected Document FFPD Exit Conveyor Not Arrived FFPD Exit Conveyor Jam FFPD Exit Conveyor Lost FFPD Input Stepper Motor Stall FFPD Exit Stepper Motor Stall FFPD Input Stepper Failed to Index Recovery Information Remove Document from unit Remove document from this unit Remove Jammed Document Press Run to Continue Find and Remove the Error document Remove an
61. bin Ensure that the back stop is fully in so that successive forms do not foul on each other Clean all the divert sensors and the collate exit sensor with an air duster Ensure that all material has been removed from the collate Unlatch the collate and remove material from the gap between the collate and the divert unit Open the divert lid and remove any material in the divert conveyor Clean all the divert sensors and the collate exit sensor with an air duster Ensure that the divert bin side guides are not too tight for the stationery being processed Ensure you are not overfilling the divert bin Ensure that the back stop is fully in so that successive forms do not foul on each other Clean all the divert sensors and the collate exit sensor with an air duster Clean all the divert sensors and the collate exit sensor with an air duster Clean all the divert sensors with an air duster Engineer action if fault persists a Check that the divert bin sensor is correctly in place and functioning correctly b Check for specific paper traps relating to the paper being processed a Check the divert entry and collate exit sensor values blocked and clear b Check for paper traps for the particular paper being used c Check that the divert 1 solenoid functions correctly d Run the divert motor in engineer and activate the divert 1 solenoid by hand and by machine control In either case ensure the divert functions easily and that ther
62. check the collate index sensor is working correctly Check operator troubleshooting Reduce the number of late diverts to fewer than 50 Track the other documents via PICS Check late divert log Ensure there are fewer than 50 labels Quit M5Go exe and re start the PC Press Clear amp restart before running the job again Check late divert log for errors Quit M5Go exe and re start the PC Press clear amp re start before running the job again If fault persists restart the application re start the PC Be careful to return documents to correct positions if re moved Check the reader is functioning correctly and the trigger is correct Investigate cause of missing page or bad read Page 53 Error Code 323 324 326 329 330 331 332 Error Message Verification Fault at Output No Read Fault at Output Too many suc cessive output verification fail ures detected No Reply from AIMS Downstream cascade feeder empty No optical doc data Wrong label length detected at reader Recovery Information Open Vertical Stacker cover check and remove envelope s before pressing run to continue Open Vertical Stacker cover check and remove envelope s before pressing run to continue Please Autoend the current job and check ALL settings are correct Check reader set up is correct Remove all Documents from the collate upper conveyor If Fault persists check all connection
63. ck that the tacho is working correctly by moving the OMR conveyor belts and watching the light on the OMR board go on and off approximately 1 flash every 2mm d Check that the OMR conveyor belts are driving correctly and that the drive collars are locked securely to the shaft Before suspecting the machine ensure that the program being used is correct for the material being processed and that the marks match those of the calibration sheet Also ensure that the material is within the company specification Re calibrate the scanner and check performance If bad read is still returned a Go to Engineer test mode and check the static performance of the scanner against the calibration sheet b Check that the tacho is working correctly by moving the OMR conveyor belts and watching the light on the OMR board go on and off approximately 1 flash every 2mm d Check that the OMR conveyor belts are driving correctly and that the drive collars are locked securely to the shaft Page 32 Error Code 171 172 173 174 Error Message Undefined OMR Barcode fault Insert Backstop limit Doubles Calibration Failed Bad sequence group in Divert Bin 1 Recovery Information Contact Technical Support Check document widths programmed for this job If problem persists call Technical Support Document may be too thick or tried to calibrate on a double Remove it and retry You may turn off thickness doubles at your own
64. ck the configuration to see which reader is selected 1 or 2 Check the switch on the OMR Barcode PCB is set to normal not test a Check functionality of scanner in test mode b Check functionality of tacho and trigger for OMR using the lights on the OMR Barcode PCB c Ensure OMR Barcode conveyor belts are locked to the drive shafts and driving without slip Ensure that the feeder on line unit side guides are sufficiently tight to control paper within 1 to 2mm a Check functionality of scanner in test mode b Check functionality of tacho and trigger for OMR using the lights on the OMR Barcode PCB c Ensure OMR Barcode conveyor belts are locked to the drive shafts and driving without slip Ensure that the feeder on line unit side guides are sufficiently tight to control paper within 1 to 2mm a Check functionality of scanner in test mode b Check functionality of tacho and trigger for OMR using the lights on the OMR Barcode PCB c Ensure OMR Barcode conveyor belts are locked to the drive shafts and driving without slip Ensure that the feeder on line unit side guides are sufficiently tight to control paper within 1 to 2mm Page 48 Error Code 263 264 265 266 267 268 269 Error Message No read group in Folder OMR No read group at Shuttle Output no read No read whilst processing voids re prints Maximum no read limit BAD Programme Output Group Sequence Error Re
65. completely clear of all documents Move the exit stepper by hand and ensure it moves freely through a complete belt cycle to detect if there is still any paper left in the unit Move the accumulator back on its slide rails and ensure that the FFPD is completely clear of all documents Move the collate stepper by hand and ensure it moves freely through a complete belt cycle to detect if there is still any paper left in the unit Engineer action if fault persists Check to ensure that the exit conveyor lid latches home correctly Check the operation of the exit stepper Check the exit conveyor sensor and the pocket sensor Check to ensure that the exit conveyor lid latches home correctly Check the operation of the exit stepper Check the exit conveyor sensor and the pocket sensor Check to ensure that the exit conveyor lid latches home correctly Check the operation of the exit stepper Check the exit conveyor sensor and the pocket sensor Check to ensure that the exit conveyor lid latches home correctly Check the operation of the exit stepper Check the exit conveyor sensor and the pocket sensor Check the operation of the collate stepper belts Check the operation of the pocket stepper belts Check sensors are working correctly Check the operation of the collate stepper belts Check the operation of the pocket stepper belts Check sensors are working correctly Check the operation of the collate stepper belts Check the operation of th
66. contact NTLIPSS Check all connections and settings are correct See AIMS and or IMOS error log file for more details If fault persists contact NTLIPSS See AIMS and or IMOS error log file for more details If fault persists contact NTL IPSS Check all connections and settings are correct See AIMS and or IMOS error log file for more details If fault persists contact NTLIPSS Check all connections and settings are correct See AIMS and or IMOS error log file for more details If fault persists contact NTLIPSS Operator action if fault persists Contact a supervisor or the IT department for support Contact a supervisor or the IT department for support Check the material being processed is for the correct job run Also check with a supervisor that the job run has not been reprinted Contact a supervisor or the IT department for support Contact a supervisor or the IT department for support Engineer action if fault persists Test network and server status If network or server status is at fault contact your IT department for support Test network and server status If network or server status is at fault contact your IT department for support Inform IT department or production department that a job run has been repeated Test network and server status If network or server status is at fault contact your IT department for support Test network and server status If network or server status is at fault contact
67. continuing Check printer software are online No communications with the envelope printer Check printer software are online Press Start to retry Remove all the documents filled envelopes from unit 0 and the document at unit 1 advanced HP press Start to continue Remove Purged Envelope from Output Vertical Stacker Check Print Quality Purge another envelope if required or press Run to continue AutoEnd the current job and Re load a new Database Operator action if fault persists Use printer instructions to ensure printer is in correct operating condition If necessary power the printer off and re boot Use printer instructions to ensure printer is in correct operating condition If necessary power the printer off and re boot Use printer instructions to ensure printer is in correct operating condition If necessary power the printer off and re boot Check sensor is clear of material and is operating correctly Follow instructions provided to clear the message Check job settings and database reference Engineer action if fault persists Re power the printer close the Flexmail application and restart Re power the printer close the Flexmail application and restart Re power the printer close the Flexmail application and restart Check serial cables and serial comms port settings Check sensor in Engineer Follow instructions provided to clear the message Test using standard database
68. covery Information Remove group from Folder OMR and manually correct Remove group from Shuttle and manually correct Check envelope contents before continuing Remove error document Press run to continue Remove all forms from unit and manually correct Barcode character has been incorrectly read check barcode setup is correct and printing is clear Check Envelope contents before continuing Operator action if fault persists Ensure scanner is correctly aligned to marks and calibrated for OMR Ensure marks are to company barcode or OMR specifications Ensure scanner is correctly aligned to marks and calibrated for OMR Ensure marks are to company barcode or OMR specifications Ensure scanner is correctly aligned to marks and calibrated for OMR Ensure marks are to company barcode or OMR specifications Check reader setup alignment etc Ensure scanner is correctly aligned to marks and calibrated for OMR Ensure marks are to company barcode or OMR specifications Barcode character has been incorrectly read check barcode setup is correct and printing is clear Ensure label design contains no illegal characters Check program and printed material are consistent Engineer action if fault persists a Check functionality of scanner in test mode b Check functionality of tacho and trigger for OMR using the lights on the OMR Barcode PCB c Ensure OMR Barcode conveyor belts are locked to the
69. d HP2 sensor values blocked and clear b Check that the collate drive belts are operating correctly without slip c Check the functionality of the HP1 and HP2 clutch and brake a Check the collate HP1 and HP2 sensor values blocked and clear b Check that the collate drive belts operate correctly without slip c Check the functionality of the HP1 and HP2 clutch and brake d Check the free running of the needle bearings on the bottom edge of the collate guide extrusion e Check the alignment between the collate conveyor side guides and the collate pocket side guides a Check that the collate drive belts are operating correctly without slip b Check the free running of the needle bearings on the bottom edge of the collate guide extrusion c Check the alignment between the collate conveyor side guides and the collate pocket side guides d Try reducing the number of balls in the collate back stop e Increase the collate pocket clearance from 2mm to 4mm f Increase the collate pocket depth in 1mm steps a Check the free running of the needle bearings on the bottom edge of the collate guide extrusion b Check the alignment between the collate conveyor side guides and the collate pocket side guides c Try reducing the number of balls in the collate back stop d Increase the collate pocket clearance from 2mm to 4mm e Increase the collate pocket depth in 1mm steps f Check the eject sensor value blocked and clear Page 14 Error
70. d enve lope at insert platform The filled envelope has not arrived at the end of the turnover Envelope has not left turnover Envelope is stopped in wetter Recovery Information Check envelope size matches the job configuration Press start to continue Remove envelope from insert platform to allow flushing to complete Remove filled envelope from insert platform turnover belts ensure belts are OK before continuing Remove filled envelope from end of turnover Press start to continue Remove filled envelope from wetter Press start to continue Operator action if fault persists Check to ensure that envelopes are not damaged before use and that the windows are securely gummed down Ensure side guides are correctly set and that envelopes are feeding squarely into the machine Always ensure that the divert assembly opened with the black handle is securely latched down Remove all material from the insert platform Clean the flap sensor with an air duster if required Check remove any partially fed envelopes from HP2 lift the insert top plate to gain access Ensure that the turnover belts are correctly in place and are driving the envelope around the turnover Check the setting of the adjustable spring guide under the insert head Check to ensure that the insert is fully in the envelope If not then make suitable adjustments to the insert area Ensure that the correct envelope size is being u
71. d the flap sensor Check the functionality of HP2 and its free return movement Using Engineer check a The mechanism motor drive freely in both directions b The index sensor is working correctly c the clock sensor is working correctly Check for any other obstructions to movement Using Engineer check a The mechanism motor drive freely in both directions b The index sensor is working correctly c the clock sensor is working correctly Check for any other obstructions to movement Using Engineer check a The mechanism motor drive freely in both directions b The index sensor is working correctly c the clock sensor is working correctly Check for any other obstructions to movement Remove the rear cover of the conveyor Remove the motor drive belt and manually raise and lower the conveyor The lift mechanism should have free movement Check the motor operates correctly with the belt removed Advise the customer that their stationery contains more than one job number in the run Advise the customer that their stationery contains more than one job number in the run Page 70 Error Code 610 611 612 613 614 615 Error Message Job Number Has Changed Communication Error with Vailipost Job Number Not Acknowledged from Valipost Job number confirmation has failed No reply from Valipost PC Unrecognized mail piece detected by Valipost Recovery Information Please Remove all the D
72. e No reply from card feeder Autoending with an empty downstream feeder Envelope has not arrived at opener Envelope has stopped in opener Unopened envelope has not been fully ejected from eject area Recovery Information Check ALL connections and that the card feeder is ready not in a fault condition Press start to continue Re load empty feeder or if no more documents available then remove the documents from the up stream IT rack to allow the Autoend process to complete Press start to continue Open Divert assembly and remove envelope from opener area Press start to continue Open Divert assembly and remove envelope from opener area Press start to continue Open Divert assembly and remove envelope from reject rollers Press start to continue Operator action if fault persists Check power to feeder Check fault light is extinguished when faults are cleared at the feeder Check cover switches function correctly NA Check that the pivoting plate carrying the 4 rollers at the entry to the opener is securely latched down Using an air duster clean the opener entry and opener flap sensors Always ensure that the divert assembly opened with the black handle is securely latched down Check that the pivoting plate carrying the 4 rollers at the entry to the opener is securely latched down Using an air duster clean the opener entry and opener flap sensors Always en
73. e TQM problem Comms failure between the machine and TQM check both units are ready powered on Clear TQM fault so job can be resumed Ensure there are no filled envelopes blocking the stepper Clean index sensor with an air duster Remove filled envelopes from VS input area Check spring guide tapes are adjusted correctly Check that there are no obstructions to the VS belt path Check that the VS belts are not damaged and that all the pawls are in place Engineer action if fault persists Check the functionality of the wheel sensor Ensure the lat est wheel sensor is fitted TB1530 203 Check all serial cables and serial comm port settings TQM is in a fault condition and not ready to accept the next filled envelope Fix the TQM problem Check the serial cable from the machine unit zero control board J12 is connected to the TQM and is not damaged TQM has detected a fault please check TQM for exact fault Check stepper in engineer mode check index sensor in engineer mode Check VS in at the correct height to the machine Ensure the side guide is set correctly giving approx 10mm clear ance for the envelope width Check filled envelopes are sealing correctly Check condition of pawled belts Check that motor pulley is securely locked to the motor shaft Check the VS input index sensor blocked and clear and the VS track clock sensor blocked and clear Run the stepper in Engineer screen and check the returned number of cl
74. e company specification Re calibrate the scanner and check performance If bad read is still returned a Go to Engineer test mode and check the static performance of the scanner against the calibration sheet b Check that the tacho is working correctly by moving the OMR conveyor belts and watching the light on the OMR board go on and off approximately 1 flash every 2mm c Check that the OMR conveyor belts are driving correctly and that the drive collars are locked securely to the shaft Page 37 Error Code 194 195 196 197 Error Message Folder OMR bad sequence Shuttle can not feed because the track is blocked OMR mismatch in Collator OMR mismatch in Divert Bin 1 Recovery Information Remove all documents from unit Manually correct the current set and any following sets Remove paper from the track and restart the machine Remove documents from Collator Manually correct the current set and any following sets Remove documents from Divert Bin 1 and manually correct Operator action if fault persists Check that the marks are aligned with the OMR head Check that the marks are consistently in the same place on consecutive pages Check that the print quality is OK and that no marks are partially printed Check the pitch has not been changed relative to the calibration sheet Carefully clean the scanner lenses ask Technical Support for help in doing this if required Check that the d
75. e driving correctly and that the drive collars are locked securely to the shaft a Check by hand that the load on the motor is normal and that there is no binding in the mechanism which the motor has to drive b Disconnect the motor from the mechanism so that it operates without load and check functionality c Check that the connectors are securely in place on the module hybrid PCB and that none of the wires are loose or broken d Check that there is no local heating of the power connector 3 pin connector and that there are no signs of burning around the connector Page 27 Error Code 147 148 149 150 Error Message Collator Hybrid Motor failed to achieve speed Folder Hybrid Motor failed to achieve speed Turnover Hybrid Motor failed to achieve speed Closer Motor failed to achieve speed Recovery Information Press Start to continue If fault persists call Technical Support Press Start to continue If fault persists call Technical Support Press Start to continue If fault persists call Technical Support Press Start to continue If fault persists call Technical Support Operator action if fault persists Ensure that all paper has been removed from the unit Ensure that all paper has been removed from the unit Ensure that all paper has been removed from the unit Ensure that all paper has been removed from the unit Engineer action if fault persists a Check by hand that the l
76. e is not excessive load imparted by the drive shaft against the movement of the divert solenoid e Check the operation of divert solenoid 2 f Check the functionality of the divert bin 2 sensor a Check that the divert bin sensor is correctly in place and functioning correctly b Check for specific paper traps relating to the paper being processed a Check for specific paper traps relating to the paper being processed b Check the values of the divert entry and collate exit sensors both clear and blocked c Check that the divert 1 solenoid functions correctly d Run the divert motor in engineer and activate the divert 1 solenoid by hand and by machine control In either case ensure the divert functions easily and that there is not excessive load imparted by the drive shaft against the movement of the divert solenoid a Check the values of the divert entry and divert exit sensors clear and blocked b Check the divert clutch is operating and that it does not bind when off c Check that the divert brake works correctly and does not bind when off Page 30 Error Code 162 163 164 165 166 167 Error Message Unexpected document at Divert Exit Document jam at Divert Exit Collate Pocket full Collator not latched home Insert Track Stepper out of position Parity Error at Collate Recovery Information Remove jam and retry Remove jam and retry Unload over size group from Collate Pocket a
77. e pocket stepper belts Check sensors are working correctly Page 75 Error Code 765 766 767 768 769 770 771 772 Error Message FFPD Exit Stepper Failed to Index Corrupt Group at FFPD Exit FFI Mailer Not Ready FFI Seriial Communication Error FFI Serial Communication Timeout FFI Inserter Not Responding to serial communications FFI Serial Com munications Lost FFI Inserter in Fault Condition Recovery Information Check and Remove any documents in the unit Remove the Corrupt group manually correct as required Press Run to continue Please wait NACK error Last message was rejected Check all cables settings are correct Timeout error Last message was rejected Check all cables settings are correct Check all settings and cables If Fault Persists contact IPSS Check all settings and cables before pressing run to continue See FFI Inserter screen for more details Resolve Error before pressing run to continue Operator action if fault persists Move the accumulator back on its slide rails and ensure that the FFPD is completely clear of all documents Move the exit stepper by hand and ensure it moves freely through a complete belt cycle to detect if there is still any paper left in the unit This is a correct operating message If you do not want this message to appear then change the job settings to change the destination of material being processed
78. e transport belts and do not cause the envelopes to catch on their leading edge Page 6 Error Code 23 24 25 26 27 Error Message Too many envelope rejects Opener Side Guide Sync Blocked Successful thickness checker calibration OMR printing error detected Oversize Group Destination Not Compatible with AIMS Recovery Information Check loading of envelopes and re calibrate doubles Remove Envelope from the Opener Hold Point HP1 Press start to continue Check the contents of the calibrated envelope If all OK then press start to continue or change settings and re calibrate Both EOG and demand mark are printed on the document Please remove error documents Press run to continue Change the destination for oversize groups in the IMOS configuration settings so that they are not sent to the output Operator action if fault persists Check that envelopes are not partially gummed down Check that the configuration chosen with the job is correct for the envelope size being used Always ensure that the divert assembly opened with the black handle is securely latched down Check HP is clear of envelopes Clean the sensor with an air duster if required Remove all envelopes from the envelope path on unit 0 NA Check printing on documents is correct to program Re calibrate OMR reader if MS9 scanner Check camera setup if using multi or automulti camera system ROI
79. eck that the handover pawled belts are not obstructing the kicker belts Clean the paper sensor with an air duster Check that there are no obstructions to the turnover eject stepper Clean the paper sensor with an air duster Check to ensure that there are no obstructions to the insert track 1 paper path and the insert platform Check that the kicker belts are not obstructing the path of paper from the station 1 track and handover Clean the insert track advanced sensor on station 1 and the document at insert platform sensor with an air duster Clean the flap sensor with an air duster Using a clean cloth moistened with clean water clean all the tyres of the envelope path Engineer action if fault persists Before making any other checks ensure that the shuttle bed sensor blocked and clear a Check condition of pawled belts b Check the shuttle index sensor blocked and clear and the shuttle clock sensor blocked and clear Before making any other checks ensure that the insert track top insert track Bottom and insert track advanced sensors are correct blocked and clear a Check condition of pawled belts b Check the i track index sensor blocked and clear and the i track clock sensor blocked and clear Before making any other check ensure that the document at insert sensor and insert track 1 advanced sensor are correct both blocked and clear a Check condition of pawled belts b Check the handover index sensor blocked and clea
80. ections Check Valipost is powered on and is working correctly Check that Valipost has the correct database for the job being processed Page 71 Error Code 616 617 618 620 621 622 623 624 Error Message Wrong job number detected by Valipost Wrong piece ID detected by Valipost Valipost has requested the inserter to stop Unexpected document at Cutter Interface HP Document Not Arrived at Cutter Interface HP Document Lost From cutter Interface HP Document Jam at Cutter Interface 2 Forms Doc Data Records at the Cutter Interface Recovery Information Check Valipost database for details Check error document destination vertical stacker input Check Valipost database for details Check error document destination vertical stacker input Check Valipost database for details Check envelopes at output vertical stacker Remove documents from Cutter Interface Remove documents from Cutter Interface Remove documents from Cutter Interface Remove documents from Cutter Interface Remove documents from the unit and continue Check Document grouping is correct Operator action if fault persists Check that Valipost has the correct database for the job being processed Check that Valipost has the correct database for the job being processed Check that Valipost has the correct database for the job being processed Check to ensure that no material ha
81. ed Critical Error General AIMS Error Error Connection Already Live with different Parameters Job ID is Not Valid Recovery Information Check all connections and settings are correct See AIMS and or IMOS error log file for more details If fault persists contact NTLIPSS Check all connections and settings are correct See AIMS and or IMOS error log file for more details If fault persists contact NTLIPSS Check all connections and settings are correct See AIMS and or IMOS error log file for more details If fault persists contact NTLIPSS Check all connections and settings are correct See AIMS and or IMOS error log file for more details If fault persists contact NTLIPSS Job Id has no Database on AIMS See AIMS and or IMOS error log file for more details Operator action if fault persists Contact a supervisor or the IT department for support Contact a supervisor or the IT department for support Contact a supervisor or the IT department for support Contact a supervisor or the IT department for support Contact a supervisor or the IT department for support Engineer action if fault persists Test network and server status If network or server status is at fault contact your IT department for support Test network and server status If network or server status is at fault contact your IT department for support Test network and server status If network or server status is at fault contact
82. eject Remove Jammed Document Press Run to Continue Find and Remove the Error document Remove Document from unit Remove document from this unit Remove Jammed Document Press Run to Continue Find and Remove the Error document Operator action if fault persists Check the configuration is requesting the correct camera and barcode function Move the accumulator back on its slide rails and ensure that the FFPD is completely clear of all documents and any material preventing mechanical operation of the diverting arms Move the accumulator back on its slide rails and ensure that the FFPD is completely clear of all documents and any material preventing mechanical operation of the diverting arms Move the accumulator back on its slide rails and ensure that the FFPD is completely clear of all documents and any material preventing mechanical operation of the diverting arms Move the accumulator back on its slide rails and ensure that the FFPD is completely clear of all documents Move the accumulator back on its slide rails and ensure that the FFPD is completely clear of all documents Move the accumulator back on its slide rails and ensure that the FFPD is completely clear of all documents Move the accumulator back on its slide rails and ensure that the FFPD is completely clear of all documents Move the accumulator back on its slide rails and ensure that the FFPD is completely clear of all documents Engineer action if f
83. ensor operates correctly Check the drive clutch and brake of the cutter interface operate correctly Check the interface sensor operates correctly Check the drive clutch and brake of the cutter interface operate correctly Check the interface sensor operates correctly Page 72 Error Code 625 626 627 628 629 700 Error Message Paper Not Loaded or Webs Not Aligned in the Cutter No Commun ications with the Cutter Synchronization Marker Not Found Merger Empty and Synchronization Marker Not Found Cutter is OFFLINE AutoRead Camera Stepper has Stalled Recovery Information Load or align paper in cutter Check cutter display for details Check all connections and settings at the inserter and the cutter Press Start to continue Check cutter display for exact error and re align web s Remove ALL documents from cutter interface and the accumulator Press Start to continue Either re load paper or press Autoend to finish the job run Check cutter is online not in programming mode Correct any fault found Check Mechanism is free If fault persists call Technical Support Operator action if fault persists Check that material is correctly loaded in the cutter Manually feed forms from both webs Check to ensure that the cutter is setup and On Line Check the alignment of the synchronisation marks on the material being processed with the sync Sensor position Check t
84. envelope size is being used with this job Ensure the wetter assembly is correctly positioned for the envelope flap being processed Ensure there are no obstructions in the wetter bits of removed envelopes Ensure that the inserts are correctly inserted into envelopes If not then make adjustments at the insert area Using an air duster clean the closer and eject sensors Ensure any output device franker is operating correctly Clean the eject and closer sensors using an air duster Grouping control on the documents or within the control file are incompatible with the job settings Engineer action if fault persists a Check the closer and eject sensor values clear and blocked b Check for obstructions in the wetter c Check for free running of all the pressure rollers on the roller carrier extrusion d Check that an even pressure is achieved between every roller on the roller carrier and the drive belts use the adjustable collars that support the wetter bed to adjust the bed height e Ensure that the closer guide spring item 29 section 4a 18 is in the correct position a Check the closer and eject sensor values clear and blocked b Check for obstructions in the wetter c Check for free running of all the pressure rollers on the roller carrier extrusion d Check that an even pressure is achieved between every roller on the roller carrier and the drive belts use the adjustable collars that support the wetter bed to adjus
85. er Check the connectors to the cutter are securely fitted Check the tension of the guide springs on the SOL unit Check the functionality of the HP1 and HP2 solenoids Ensure all documents are removed from the unit and the covers are opened and closed Ensure all documents are removed from the unit and the covers are opened and closed Engineer action if fault persists Check the serial connection and the serial comm port settings Check the serial connection and the serial comm port settings Check the serial connection and the serial comm port settings See Operator Advice Use the trace tool to check if documents are catching up between HP1 and HP2 Check functionality of solenoids and solenoid stop mechanisms Ensure all documents are removed from the unit and the covers are opened and closed Check sensor values in Engineer Ensure all documents are removed from the unit and the covers are opened and closed Check sensor values in Engineer Page 67 Error Code 526 530 531 540 541 542 543 550 Error Message 2 Forms 2 Doc Data Records at Collate Turnover Track Guide re sync Required Track Guide re sync Complete Envelope in VS entry position 0 was due to be Jogged Envelope in VS entry position 1 was due to be Jogged Envelope in VS position 2 was due to be Jogged Envelope in VS position 3 was due to be Jogged Duplicate Document in Sheet Dive
86. er Press start to continue Remove documents from Insert platform Press start to continue Remove documents from end of turnover Press start to continue Remove documents from insert area and unit 1 transfer Remove documents from insert platform Press start to continue Operator action if fault persists Check that there are no obstructions to the shuttle stepper Check that the shuttle belts are not damaged and that all the flights are in place Check that the insert track stepper belts are not obstructing the shuttle belts Check to ensure that the shuttle adjustable tapes are not too strong causing the document on the shuttle bed to hold back the belts Clean the paper sensor with an air duster Check that there are no obstructions to the insert track path Check that the track belts are not damaged and that all the pawls are in place Check that the shuttle belts are not obstructing the insert track belts Clean the paper sensor with an air duster Check that there are no obstructions to the handover stepper Check that the insert platform is clear of any paper Check that the handover belts are not damaged and that all the pawls are in place Check that the kicker pawled belts are not obstructing the handover belts Check that insert track 1 advanced is clear of paper Clean the paper sensor with an air duster Check that there are no obstructions to the kicker on either the insert platform or on top of the turnover Ch
87. er left in the blade or side trimmers before re loading Check brushes are not too tight Check that there is no paper left in the blade or side trimmers before re loading Check brushes are not too tight Check brushes are not too tight Check speed of job is not too high for perforation type Check web calmer is correctly positioned Engineer action if fault persists a Check that output wheels on cutter are driving the removed sprockets away from the paper path b Check blade sharpness c Check paper sensor and paper out microswitch Check adjustment of cutter microswitch cam Check functionality of switch replace if necessary a Ensure all faults are cleared b Ensure correct program is selected Check all connections into the cutter Check all connec tions on the cutter interface board Check calibration of sensor Check calibration of sensor Check web calmer is operating correctly and that distance between cutter and merger is correct Page 50 Error Code 278 279 280 281 282 283 284 285 286 290 Error Message Cutter paper switch TR2 clear FLT_CUTTER_ DATA_ERROR Too many forms at shuttle Envelope jam at franker 2 FLT_I2C_ BUFFER_FULL Envelope has not arrived at Franker Exit Sensor Envelopes too close together at Exit sensor Incomplete group at shuttle Incomplete group in collate Prime station has moved Recovery Information
88. ere are no obstructions Check wheel passing through the conveyor without obstruc tion Check alignment and that the conveyor height is correct and the conveyor is level Ensure all material is removed from the VS wheel Ensure that you are correctly removing documents from the VS in the event of a crash in the VS Ensure that the wheel sensor is operating correctly and is not fouled by a paper blockage Contact IPSS for help Blow out any paper dust in the mechanism using an air duster Remove second paddle if it is blocking the conveyor full switch Re power the vertical stacker Engineer action if fault persists Check that there are no obstructions to the VS Wheel path Check that the VS fingers are not damaged and that all pass through the conveyor Clean the sensor with an air duster Check that there are no obstructions to the VS Wheel path Check that the VS fingers are not damaged and that all pass through the conveyor Check index sensor is working also check the condition of the drive belts pulleys Check the functionality of the wheel sensor Ensure the lat est wheel sensor is fitted TB1530 203 Contact IPSS for help Check the free running of the motor over its full range in Engineer If the motor is struggling to move the mechanism disassemble the mechanism and check that a The slider slides freely up and down the slide shaft b The belt is clamped firmly between the slider and the stop plate
89. freely when not attached to the mechanism Also check the top hat sensor goes blocked and clear Check VS input sensor and VS side guide sensor works correctly Manually feed an envelope into the VS input check alainment check for catch points check VS height the height of the input ramp is critical Check the Vertical Stacker input sensor is not faulty If Fault persists then replace the sensor Page 65 Error Code 510 511 512 513 514 515 516 517 Error Message Vertical Stacker Wheel No Index Vertical Stacker Wheel Stall Vertical Stacker Wheel Jam Vertical Stacker Envelope Lost Vertical Stacker set to Stand Alone Mode Vertical Stacker Brush Stall Vertical Stacker Output Conveyor Full Vertical Stacker Not Received Config from Unit 0 Recovery Information Remove Envelopes from the wheel and retry If fault persists call Technical Support Remove filled Envelope Press Start to continue Remove jam and retry Remove ALL Envelopes from the VS Press Start to continue Check all settings and Press clear and restart and try again Remove filled Enve lopes from conveyor so VS brush can sync Empty Conveyor Remove paddle and press start to continue Press OK and then Run to Continue IF fault persists Power Cycle the Vertical Stacker and then reset unit 0 Operator action if fault persists Ensure all material is removed from the VS wheel and th
90. from WJPro IJ 15K No Status Message Received from WJPro IJ 15K Checksum Error on the Message received from W4JPro IJ 15K No Error Message Received from W4JPro IJ 15K Recovery Information Instructions for Details Check the Franker Display for exact Fault See Franker Instructions for Details of how to clear the fault Check the Franker for exact Fault See Franker Instructions for Details of how to clear the fault Wait for head cleaning to finish Inserter will Auto Start when head cleaning is complete Check the franker is online and that all settings are correct Check the franker is online and that all settings are correct Check the franker is online and all settings are correct Check the franker is online and that all settings are correct Operator action if fault persists Use the IJ 15K WJ Pro instructions to ensure the meter is in the correct operating condition If necessary power the meter off and re boot Use the IJ 15K WJ Pro instructions to ensure the meter is in the correct operating condition If necessary power the meter off and re boot Use the IJ 15K WJ Pro instructions to ensure the meter is in the correct operating condition If necessary power the meter off and re boot Use the IJ 15K WJ Pro instructions to ensure the meter is in the correct operating condition If necessary power the meter off and re boot Use the IJ 15K WJ Pro instructions to ensure the meter is in the
91. fully home Refill empty station Check separator settings Operator action if fault persists Check that all the shuttles are correctly down in position If fault persists call Technical Support Ensure that the Sealing fluid container at the back of the machine is not empty and that the pipe is below the surface of the water Ensure that there are no obstructions under the hi cap trolley that would prevent it from lowering down Ensure that the side guides are set slightly greater than the width of the material Make sure Trolley is fully home Clean the feed tyres using a clean cloth with clean water Ensure the side guides of the feed trolley are not too tight Re calibrate doubles and try again Check to ensure that the doubles sensor is not aligned with solid black print if it is then contact technical support for help Clean all feed and transport wheels with a clean cloth and clean water Ensure that the pressure assembly is correctly latched home Clean the doubles sensor using an air duster Engineer action if fault persists a Check that the insert track top insert track bottom and insert track advanced for the station concerned and the upstream and downstream stations are correct both blocked and clear b Check that the solenoid stops are functioning correctly a Run the mask motor in Engineer and ensure it travels over its full range without hesitation note that care should be taken when using the Engineer
92. hannel Prime Document is trying to select from a feeder that is empty Recovery Information Check Franker for Details Press Run to Continue Check the franker is online and all settings are correct Check Franker for Details Press Run to Continue If you like to ignore the error and continue processing press OK and than RUN to continue Otherwise press Cancel Processing has stopped due to loop switch detecting an error Correct paper loop web error Check Stop switch is deactivated and Press Go to continue Please Remove ALL documents from the unit and then correct the next tractor TR1 TR2 to feed from the cutter Either reload the feeder or remove the document from the Itrack Press Run to continue Operator action if fault persists Use the IJ 15K WJ Pro instructions to ensure the meter is in the correct operating condition If necessary power the meter off and re boot Use the IJ 15K WJ Pro instructions to ensure the meter is in the correct operating condition If necessary power the meter off and re boot Check the settings of the meter Watch the meter screen when the run button is pressed from the DS 1XXX to en sure it is communicating Check the loop switch is blocked by the web Check the loop switch is blocked by the web Check to ensure that the stop button is not depressed by material placed on top Advance the top or bottom web to correct the sequence Set the correct
93. hat envelopes are feeding squarely into the machine Always ensure that the divert assembly opened with the black handle is securely latched down Engineer action if fault persists Advise the customer of label characters for changing machine control Check the blocked and clear values of the HP sensor Check that the side guide motor runs backwards and for wards in engineer mode If mechanism is struggling to drive the assembly the dismantle and check for damage Check the leadscrew is not damaged Check the side guides are not bent distorted adjust if required Check the motor drives correctly when not attached to the mechanism a Check the opener entry opener flap and envelope opener conveyor HP1 sensor values clear and blocked b Run the hybrid motor for the envelope feed and ensure that all drives are running freely and can be loaded without causing slippage c Check that the opener extrusion is pivoting freely and that the return spring is in place a Check the HP1 sensor is correct clear and blocked b Check the drives to the conveyor are running freely c check that the pressure rollers in the divert assembly are running freely and that the white springs are in place on the front pressure shaft the one with the rubber tyres d Check the solenoid fires correctly and that the stop drops below the conveyor bed by at least 1mm a Check the HP1 sensor is correct clear and blocked b Check the drives to the conveyor are
94. hat the kicker pawled belts are not obstructing the handover belts Check that there are no obstructions to the collate stepper Check that the collate belts are not damaged and that all three backstops are in place Check to ensure that envelopes are not damaged before use and that the windows are securely gummed down Ensure side guides are correctly set and that envelopes are feeding squarely into the machine Always ensure that the divert assembly opened with the black handle is securely latched down Check that there are no obstructions to the shuttle stepper Check that the shuttle belts are not damaged and that all the pawls are in place Check that the insert track stepper belts are not obstructing the shuttle belts Check to ensure that the shuttle adjustable tapes are not too strong causing the document on the shuttle bed to hold back the belts Engineer action if fault persists a Check condition of pawled belts b Check that motor pulley is securely locked to the motor shaft this is a flexible coupling and should be securely clamped at both ends c Check the handover index sensor blocked and clear and the handover clock sensor blocked and clear d Run the stepper in Engineer screen and check the returned number of clocks forward and back These should be equal in both directions to within 2 clocks e While still in Engineer stepper test add resistance to the pawls and watch the change in returned clocks This should g
95. he alignment of the synchronisation marks on the material being processed with the sync Sensor position Check the setup of the cutter Ensure the cutter is set to On Line before proceeding Use an air duster to clean the mechanism Use a cloth to clean the slide shaft and surfaces on which the transport bearings move Engineer action if fault persists Check all electrical connections with the cutter Check the calibration of the sensor Ensure the sync Light turns ON and OFF when the mark is passed under the sensor Check the calibration of the sensor Ensure the sync Light turns ON and OFF when the mark is passed under the sensor Check a The mechanism motor drive freely in both directions b The index sensor is working correctly Check for any other obstructions to movement Page 73 Error Code 701 750 751 752 753 754 755 756 757 Error Message Camera Needs to be Changed Wait for LIS PC to Power down Power down the Inserter FFPD Collate Unexpected Document FFPD Collate Not Arrived FFPD Collate Jam F FPD Collate Lost FFPD Pocket Unexpected Document FFPD Pocket Not Arrived FFPD Pocket Jam FFPD Pocket Lost Recovery Information Unplug the camera cables and fit the required camera Re fit all cables Power the camera PC Power the Inserter Press Clear and restart to continue Remove Document from unit Remove document from this unit the collate
96. he calibration sheet Also ensure that the material is within the company specification Re calibrate the scanner and check performance If bad read is still returned a Go to engineer test mode and check the static performance of the scanner against the calibration sheet b Check that the tacho is working correctly by moving the OMR conveyor belts and watching the light on the OMR board go on and off approximately 1 flash every 2mm d Check that the OMR conveyor belts are driving correctly and that the drive collars are locked securely to the shaft No action a Check that the doubles sensor will return sensible values when calibrated on 80gsm paper b Check that the material being used does not present a solid black print to the doubles detector If so then move the sensor across away from the solid black area c Check that all the drives are functioning correctly and that there is no paper slip Before suspecting the machine ensure that the program being used is correct for the material being processed and that the marks match those of the calibration sheet Also ensure that the material is within the company specification Re calibrate the scanner and check performance If bad sequence is still returned a Go to Engineer test mode and check the static performance of the scanner against the calibration sheet b Check that the tacho is working correctly by moving the OMR conveyor belts and watching the light on the OMR board go on a
97. heck that drive belts are running freely b Check the gap between the wetter sponge and the top and bottom guides to ensure envelope is not being trapped c Check for free running of all the pressure rollers on the roller carrier extrusion d Check that an even pressure is achieved between every roller on the roller carrier and the drive belts use the adjustable collars that support the wetter bed to adjust the bed height Page 10 Error Code 43 44 45 46 47 Error Message Envelope is Stopped in closer Envelope is Stopped in closer An unexpected document has arrived at eject A filled envelope has not cleared the eject AIMS Error Due to Forms in Group Equalling Zero Recovery Information Remove filled envelope from closer Press start to continue Remove filled envelope from closer Press start to continue Remove any items at the eject Press start to continue Remove filled envelope from eject Press start to continue Check AIMS for Details If fault persists contact NTL IPSS Operator action if fault persists Ensure that the correct envelope size is being used with this job Ensure the wetter assembly is correctly positioned for the envelope flap being processed Ensure there are no obstructions in the wetter bits of removed envelopes Ensure that the inserts are correctly inserted into envelopes If not then make adjustments at the insert area Ensure that the correct
98. heck the last en velope processed is logged correctly Au toend the current job and press clear and re start before running again Operator action if fault persists Check to ensure that documents are being driven from the shuttle to the Datum plate and blocking the Itrack top sen sor Your track advanced sensor is becoming blocked due to machine stoppages caused by the shuttle or Itrack pocket Check the adjustments of the shuttle to ensure documents are arriving cleanly at the Itrack pocket Check to ensure that you are running the correct job Check to ensure you have not continued processing when the job number on the documents has changed Re calibrate doubles using the doubles cal button on the run screen Check to ensure you are not running a duplicated job Ensure that you are correctly removing documents from the VS in the event of a crash in the VS Ensure that the wheel sensor is operating correctly and is not fouled by a paper blockage Engineer action if fault persists Check the track top sensor is going blocked and clear cor rectly Look at the settings for the unit to ensure paper handling at the shuttle bed shuttle and Itrack are correct and allowing clean operation of these areas Advise the customer that their stationery contains more than one job number in the run Check to ensure that the doubles sensor is operating cor rectly Take a trace and look for the Thk values in the trace
99. ift Remove all documents from the machine and manually re calibrate sensors Check that the marks are aligned with the OMR head Check that the marks are consistently in the same place on consecutive pages Check that the print quality is OK and that no marks are partially printed Check the pitch has not been changed relative to the calibration sheet Carefully clean the scanner lenses ask Technical Support for help in doing this if required Engineer action if fault persists a Check that the doubles sensor will return sensible values when calibrated on 80gsm paper b Check that the material being used does not present a solid black print to the doubles detector If so then move the sensor across away from the solid black area c Check that all the drives are functioning correctly and that there is no paper slip a Check that all the drives are functioning correctly and that there is no paper slip b Check that all the roller clutches are free running and do not bind up c Check that the separator is not too tight on 80gsm paper d Check all the downstream drives are taking the paper away correctly particularly the OMR barcode drive belts Check sensors are correctly seated in sensor bracket Check functionality of sensors Turn doubles detection OFF and test functionality of the machine without doubles detection Turn doubles back on and retest Test the sensor in engineer Before suspecting the machine ensure that the p
100. ive an indication of the strength of the stepper f Check that the handover belt pawls are not hitting any part of the insert platform a Check condition of the belts b Check that motor pulley is securely locked to the motor shaft c Check the collate index sensor blocked and clear and the collate disk sensor clear and blocked a Check the flap sensor value blocked and clear b Check that the solenoid at HP2 is operating correctly c Check that the stop is rotating freely d Check that the stop goes down below the bed by at least 1mm e Check the pressure between the flap gripper rollers and the needle bearing on the insert plate is tight f Run the stepper in Engineer and check that clocks returned are consistent a Check condition of pawled belts b Check that motor pulley is securely locked to the motor shaft c Check the shuttle index sensor blocked and clear and the shuttle clock sensor blocked and clear d Run the stepper in Engineer screen and check the returned number of clocks forward and back These should be equal in both directions to within 2 clocks e While still in Engineer stepper test add resistance to the pawls and watch the change in returned clocks This should give an indication of the strength of the stepper Page 17 Error Code 91 92 93 Error Message Insert Track stepper failed to index Turnover Eject stepper failed to index Kicker stepper failed to index Recovery Inform
101. justed Check configuration for Jog is correct Check adjustments for VS to the inserter are OK Check to see if the VS entry tapes are correctly adjusted Check the material being processed is for the correct job run Also check with a supervisor that the job run has not been reprinted Engineer action if fault persists Ensure all documents are removed from the unit and the covers are opened and closed Check sensor values in Engineer Check that the short on long guides are in good condition and are not causing catch points on either the shuttle or the track guides Check for free movement of the track guides during re sync See Operator Advice Ensure entry side guide and wheel sensors are working correctly Ensure the stepper motors for the track and wheel both function correctly Ensure entry side guide and wheel sensors are working correctly Ensure the stepper motors for the track and wheel both function correctly Ensure entry side guide and wheel sensors are working correctly Ensure the stepper motors for the track and wheel both function correctly Ensure entry side guide and wheel sensors are working correctly Ensure the stepper motors for the track and wheel both function correctly Inform IT department or production department that a job run has been repeated Page 68 Error Code 551 552 553 560 599 601 602 Error Message Duplicate Document in Sheet Divert Bin 2 Invalid
102. k that motor pulley is securely locked to the motor shaft c Check the shuttle index sensor blocked and clear and the shuttle clock sensor blocked and clear d Run the stepper in Engineer screen and check the returned number of clocks forward and back These should be equal in both directions to within 2 clocks e While still in Engineer stepper test add resistance to the pawls and watch the change in returned clocks This should give an indication of the strength of the stepper a Check that the vane moves when adjusted on the cam if the return spring is weak then the cam will move during operation and cause the fingers to hunt b Check that the motor pulley is securely locked to the motor c Check that the middle fingers are not over adjusted i e they are not hitting metalwork in either the forward or backward directions d Check the finger vane sensor blocked and clear a Check condition of pawled belts b Check that motor pulley is securely locked to the motor shaft c Check the turnover eject index sensor blocked and clear and the turnover eject clock sensor blocked and clear d Run the stepper in Engineer screen and check the returned number of clocks forward and back These should be equal in both directions to within 2 clocks e While still in Engineer stepper test add resistance to the pawls and watch the change in returned clocks This should give an indication of the strength of the stepper a Check condi
103. l Feeder motor stall Folder motor stall Turnover motor stall Recovery Information Remove documents in Insert area and retry If fault persists call Technical Support Remove documents in Collate Pocket and retry If fault persists call Technical Support Remove all document from the unit Press start to continue Remove all document from feeder Re load and press start to continue Remove all paper from folder feeder and folder Press start to continue Ensure turnover disks rotate freely Press start to continue Operator action if fault persists Check that there are no obstructions to the handover stepper Check that the handover belts are not damaged and that all the pawls are in place Check that the kicker pawled belts are not obstructing the handover belts Check that there are no obstructions to the collate stepper Check that the collate belts are not damaged and that all three backstops are in place Check to ensure the rollers of the drive unit are free to turn and that there are no obstructions Check that all paper is removed from the feed path Clean all sensors in the feeder using an air duster Check that the separator gap is correct for the material being processed Check that the fold settings are correct for the material being processed Pivot down Fold plate assembly 1 3 and ensure no material is left in the fold plates Ensure material is correctly loaded in feed hoppers Clean fold ro
104. llers using roller cleaning fluid Check that there is no material left in the turnover Ensure turnover belts are located correctly on the turnover disks Engineer action if fault persists a Check condition of pawled belts b Check that motor pulley is securely locked to the motor shaft this is a flexible coupling and should be securely clamped at both ends c Check the handover index sensor blocked and clear and the handover clock sensor blocked and clear d Run the stepper in Engineer screen and check the returned number of clocks forward and back These should be equal in both directions to within 2 clocks e While still in Engineer stepper test add resistance to the pawls and watch the change in returned clocks This should give an indication of the strength of the stepper f Check that the handover belt pawls are not hitting any part of the insert platform a Check condition of the belts b Check that motor pulley is securely locked to the motor shaft c Check the collate index sensor blocked and clear and the collate disk sensor clear and blocked Check the electrical connections are secure and that the cover switch is operating correctly a Check that the feed clutches and brake s are not binding b Check all clutches and brakes operate correctly in Engineer c Check the 80gsm setting for the separator is correct reset if necessary d Check there are no material catch points related to the documents being proce
105. low the diverter or if a mail bag is fitted ensure bin bag is not full or that mail bag is not restricting the free fall of the envelope Edit configuration output to modify the number of envelopes or weight of envelopes in a batch If not required then turn batch off in either the configuration screen or the output twiddle screen Edit configuration output to modify the number of envelopes or weight of envelopes in a batch If not required then turn batch off in either the configuration screen or the output twiddle screen Edit configuration output to modify the number of envelopes or weight of envelopes in a batch If not required then turn batch off in either the configuration screen or the output twiddle screen Edit configuration output to modify the number of envelopes or weight of envelopes in a batch If not required then turn batch off in either the configuration screen or the output twiddle screen Edit configuration output to modify the number of envelopes or weight of envelopes in a batch If not required then turn batch off in either the configuration screen or the output twiddle screen Engineer action if fault persists a Ensure that the divert backstop setting is not too tight approximately 2mm float on envelope width with a conveyor or 12mm on envelope width with a mail bag use twiddle screen to adjust if necessary b Ensure back stop is adjusti
106. ming This is a function of stationery and programming a Check that the configuration of the current job is correct Re check operator action before assuming there is a fault a Check that both solenoid stops are working correctly b Check values of all 3 paper sensors clear and blocked c Check conveyor belts are not slipping Re check operator action before assuming there is a fault a Check that both solenoid stops are working correctly b Check values of all 3 paper sensors clear and blocked Re check operator action before assuming there is a fault a Check that both solenoid stops are working correctly b Check values of all 3 paper sensors clear and blocked c Check conveyor belts are not slipping Page 39 Error Code 209 210 211 212 213 214 Error Message S O L Hybrid motor stalled S O L Hybrid motor failed to achieve speed Document jam at S O L HP1 Unexpected document at S O L HP1 Document failed to arrive at Single Online hold point 1 Document Lost at S O L HP1 Recovery Information Remove all documents from unit Press Start to continue Press Start to continue If problem persists call Technical Support Remove documents from unit Check spring tension at HP 1 Press Start to continue Remove documents from unit Press Start to continue Check Cutter and Cut ter Interface Press Start to continue Remove documents from S O L and retry
107. n the hybrid motor in Engineer mode a Check back stop motor runs freely in engineer mode b check motor disk sensor clear and blocked c Check for mechanical damage to backstop which may be causing the mechanism to seize a Check back stop motor runs freely in engineer mode b check motor disk sensor clear and blocked c Check for mechanical damage to backstop which may be causing the mechanism to seize a Check back stop motor runs freely in engineer mode b check motor disk sensor clear and blocked c Check for mechanical damage to backstop which may be causing the mechanism to seize Re check operator action before assuming there is a fault a Check that the divert lifts and falls freely and that envelopes pass freely along the through path b Check value of eject sensor clear and blocked c Check conveyor belts are running freely Re check operator action before assuming there is a fault a Check that the divert lifts and falls freely and that envelopes pass freely along the through path b Check value of eject sensor clear and blocked c Check conveyor belts are running freely Re check operator action before assuming there is a fault a Check that the divert lifts and falls freely and that envelopes pass freely along the through path b Check value of eject sensor clear and blocked c Check conveyor belts are running freely Re check operator action before assuming there is a fault a Check that the dive
108. n the motor is normal and that there is no binding in the mechanism which the motor has to drive b Disconnect the motor from the mechanism so that it operates without load and check functionality c Check that the connectors are securely in place on the module hybrid PCB and that none of the wires are loose or broken d Check that there is no local heating of the power connector 3 pin connector and that there are no signs of burning around the connector Re check operator action before assuming there is a fault a Check that both solenoid stops are working correctly b Check values of all 3 paper sensors clear and blocked c Check conveyor belts are not slipping Re check operator action before assuming there is a fault a Check that both solenoid stops are working correctly b Check values of all 3 paper sensors clear and blocked Re check operator action before assuming there is a fault a Check that both solenoid stops are working correctly b Check values of all 3 paper sensors clear and blocked c Check conveyor belts are not slipping d Check the cutter is online and programmed correctly Check side guides are not tight and if sufficient drive guide tapes in contact with the drive belts in the cutter interface section if fitted Check the HP1 and HP2 sensor values blocked and clear Check pressure of guide springs Check that the solenoid stops are functioning correctly Page 40 Error Code 215 216 217
109. nd off approximately 1 flash every 2mm c Check that the OMR conveyor belts are driving correctly and that the drive collars are locked securely to the shaft Page 33 Error Code 175 176 177 178 179 Error Message Bad sequence group in Divert Bin 2 Bad sequence group in Shuttle Bed A filled envelope has stopped in the franker Group on Shuttle Bed has halt mark Unexpected Task Time out Recovery Information Remove forms from Divert Bin 2 and manually correct Remove forms from Shuttle Bed and manually correct Remove envelope from franker restart franker restart machine Remove group on Shuttle Bed press Start Remove all paper from this unit reset unit from the twiddle screen and press start Operator action if fault persists Check that the marks are aligned with the OMR head Check that the marks are consistently in the same place on consecutive pages Check that the print quality is OK and that no marks are partially printed Check the pitch has not been changed relative to the calibration sheet Carefully clean the scanner lenses ask Technical Support for help in doing this if required Check that the marks are aligned with the OMR head Check that the marks are consistently in the same place on consecutive pages Check that the print quality is OK and that no marks are partially printed Check the pitch has not been changed relative to the calibration sheet
110. nd continue Push Collator until fully home If fault persists call Technical Support Remove all forms from unit Manually correct current set and all following sets Operator action if fault persists Clean all the divert sensors with an air duster Clean all the divert sensors with an air duster Check the program configuration is as required Unlatch the collate slide it back and then re latch it home firmly Ensure that all material is removed from the insert track Reset unit and try again Clean all sensors including the track index sensor located at the bottom of the cassette Check that the marks are aligned with the OMR head Check that the marks are consistently in the same place on consecutive pages Check that the print quality is OK and that no marks are partially printed Check the pitch has not been changed relative to the calibration sheet Carefully clean the scanner lenses ask Technical Support for help in doing this if required Check number of marks for correct parity Check print run is correct Check correct parity Check parity mark is programmed Check correct parity mode off odd even Engineer action if fault persists a Check the values of the divert entry and divert exit sensors clear and blocked b Check the divert clutch is operating and that it does not bind when off c Check that the divert brake works correctly and does not bind when off d Check that the divert 1 solenoid functi
111. ned with the black handle is securely latched down Ensure there are no obstructions on the cover of the opener divert Always ensure that the divert assembly opened with the black handle is securely latched down Ensure there are no obstructions on the cover of the opener divert Always ensure that the divert assembly opened with the black handle is securely latched down Check to ensure that envelopes are not damaged before use and that the windows are securely gummed down Ensure side guides are correctly set and that envelopes are feeding squarely into the machine Always ensure that the divert assembly opened with the black handle is securely latched down Check to ensure that envelopes are not damaged before use and that the windows are securely gummed down Ensure side guides are correctly set and that envelopes are feeding squarely into the machine Always ensure that the divert assembly opened with the black handle is securely latched down Engineer action if fault persists a Check the HP1 sensor is correct clear and blocked b Check the drives to the conveyor are running freely c check that the pressure rollers in the divert assembly are running freely and that the white springs are in place on the front pressure shaft the one with the rubber tyres a Clean the rollers which drive the unopened envelope out of the divert cover b Ensure that there are no obstructions to the rejected envelope leaving the rejec
112. ng the rear top plate Check All Envelopes are Removed form the Envelope Path Press Start to Continue Check All Envelopes are Removed form the Envelope Path Press Start to Continue Check All Envelopes are Removed form the Envelope Path Press Start to Continue Lift Mechanism has stalled Check for obstructions damaged mechanism Please Remove all the Documents from the Shuttle Bed and Feeder HP You Must Now Autoend this Job Please Remove all the Documents from the Fold OMR unit and the Feeder HP You Must Now Autoend this Job Operator action if fault persists Check that there are no envelopes located between the opener conveyor HP2 and the flap gripper rollers Manually rotate the flap gripper rollers to eject any envelopes under the insert platform Use an air duster to clean the mechanism Use an air duster to clean the mechanism Use an air duster to clean the mechanism Ensure all material has been removed from the feed conveyor and that there are no obstructions to free movement of the lifting mechanism Check to ensure that you are running the correct job Check to ensure you have not continued processing when the job number on the documents has changed Check to ensure that you are running the correct job Check to ensure you have not continued processing when the job number on the documents has changed Engineer action if fault persists Check the functionality of the flap gripper stepper an
113. ng to the same position every time c Check value of divert sensor clear and blocked d Check solenoid adjustments are correct to provide sufficient lift to allow envelope cleanly into divert e Check divert conveyor pulses correctly and that conveyor belts do not slip f If a mail bag is fitted ensure that the bag does not restrict free fall of the envelope note that for a mail bag you can increase the back stop setting by up to 15mm above the nominal setting as the accuracy is far less important than for a divert conveyor Advise customers of use of batch counting use of batch control modes etc Advise customers of use of batch counting use of batch control modes etc Advise customers of use of batch counting use of batch control modes etc Advise customers of use of batch counting use of batch control modes etc Advise customers of use of batch counting use of batch control modes etc Page 45 Error Code 243 244 245 246 247 248 249 Error Message Bag full at Output Divert 1 Bag full at Output Divert 2 Bag full at Output Divert 3 Unexpected filled envelope at the eject sensor of unit 0 Unexpected filled envelope at the eject sensor of output divert unit 1 Unexpected filled envelope at the eject sensor of output divert unit 2 Unexpected filled envelope at the eject sensor of output divert unit 3 Recovery Information Empty Bag 1 Empty Bag 2 Empty B
114. ntact a supervisor or the IT department for support Contact a supervisor or the IT department for support Engineer action if fault persists Test network and server status If network or server status is at fault contact your IT department for support Test network and server status If network or server status is at fault contact your IT department for support Test network and server status If network or server status is at fault contact your IT department for support Test network and server status If network or server status is at fault contact your IT department for support Test network and server status If network or server status is at fault contact your IT department for support Page 82 Error Code 1058 1997 1998 Error Message Invalid Packet or String Received AIMS Not Licenced For This Product Error Detected in Data Recovery Information Check all connections and settings are correct See AIMS and or IMOS error log file for more details If fault persists contact NTLIPSS See AIMS error log file for more details If fault persists contact NTLIPSS Check Last Few Mail Pieces Processed are correctly logged in AMIS See AIMS log file for more details If fault persists contact NTLIPSS Operator action if fault persists Contact a supervisor or the IT department for support Contact a supervisor or the IT department for support Contact a supervisor or the IT department for support
115. nveyor hold point sensors with an air duster Ensure the collate conveyor and collate pocket side guides are correctly adjusted Check that there are no obstructions in the OMR Barcode unit Check there are no obstructions in the collate conveyor section Clean the collate conveyor hold point sensors with an air duster Ensure the collate conveyor and collate pocket side guides are correctly adjusted Check there are no obstructions in the collate conveyor section Clean the collate conveyor hold point sensors and the collate pocket sensor with an air duster Ensure the collate conveyor and collate pocket side guides are correctly adjusted Check there are no obstructions in the collate conveyor section Clean the collate conveyor hold point sensors and the collate pocket sensor with an air duster Ensure the collate conveyor and collate pocket side guides are correctly adjusted Ensure that the document is correct for the job configuration Clean the eject sensor using an air duster Ensure the collate conveyor and collate pocket side guides are correctly adjusted Ensure that the document is correct for the job configuration Clean the eject sensor using an air duster Engineer action if fault persists a Check the collate hp1 and HP2 sensor values blocked and clear b Check that the collate drive belts are operating correctly without slip c Check the functionality of the HP1 and HP2 clutch and brake a Check the collate HP1 an
116. oad on the motor is normal and that there is no binding in the mechanism which the motor has to drive b Disconnect the motor from the mechanism so that it operates without load and check functionality c Check that the connectors are securely in place on the module hybrid PCB and that none of the wires are loose or broken d Check that there is no local heating of the power connector 3 pin connector and that there are no signs of burning around the connector a Check by hand that the load on the motor is normal and that there is no binding in the mechanism which the motor has to drive b Disconnect the motor from the mechanism so that it operates without load and check functionality c Check that the connectors are securely in place on the module hybrid PCB and that none of the wires are loose or broken d Check that there is no local heating of the power connector 3 pin connector and that there are no signs of burning around the connector a Check by hand that the load on the motor is normal and that there is no binding in the mechanism which the motor has to drive b Disconnect the motor from the mechanism so that it operates without load and check functionality c Check that the connectors are securely in place on the module hybrid PCB and that none of the wires are loose or broken d Check that there is no local heating of the power connector 3 pin connector and that there are no signs of burning around the connector
117. ocks forward and back These should be equal in both directions to within 2 clocks While still in Engineer stepper test add resistance to the pawls and watch the change in returned clocks This should give an indication of the strength of the stepper Page 64 Error Code 502 503 504 505 506 507 508 509 Error Message Vertical Stacker Input Cannot Re Sync Vertical Stacker Input Unex pected Vertical Stacker Input Not Arrived Vertical Stacker Input Jam Vertical Stacker Side Guide Stall Vertical Stacker Side Guide Unexpected Vertical Stacker Side Guide Not Arrived Vertical Stacker Input Index Sensor Blocked Recovery Information Remove Envelope from VS Input Remove jam and retry Remove envelope from the machine output and retry Remove jam and retry Ensure there are no filled envelopes in the way the envelope sizes are correct Press Start to Continue Remove jam and retry Remove Envelope from VS input and retry Check the Vertical Stacker input sensor is not faulty If Fault persists then replace the sensor Operator action if fault persists Input sensor side guide sensor is not clear remove enve lopes or clean sensors or re calibrate Check the machine exit sensor or output divert exit sensor Ensure the filled envelope is closing sealing correctly Also that all config settings are correct for the envelope fold Ensure the filled en
118. ocument size is correct for the job configuration Clean the shuttle bed and track top and bottom sensors using an air duster Using the touch screen touch the area of track where the mismatch has occurred Find which documents are out of place and remove further documents until matching is achieved You can remove one document at a time and let the machine cycle once until the next mismatch Keep doing this until the machine brings the matching back together correctly Using the touch screen touch the area of track where the mismatch has occurred Find which documents are out of place and remove further documents until matching is achieved You can remove one document at a time and let the machine cycle once until the next mismatch Keep doing this until the machine brings the matching back together correctly Engineer action if fault persists Before suspecting the machine ensure that the program being used is correct for the material being processed and that the marks match those of the calibration sheet Also ensure that the material is within the company specification Re calibrate the scanner and check performance If bad sequence is still returned a Go to Engineer test mode and check the static performance of the scanner against the calibration sheet b Check that the tacho is working correctly by moving the OMR conveyor belts and watching the light on the OMR board go on and off approximately 1 flash every 2mm d Check that the
119. ocuments from the Collate Conveyor You Must Now Autoend this Job Check system is online and all connections are correct Press start to re try Check system is online and all connections are correct Press Clear and restart and retry Document was a NO Read so job number could not be confirmed Remove Document and Press go to continue Check all connections and settings both in IMOS and at the Valipost PC Check Valipost database for details Check error document destination vertical stacker input Operator action if fault persists Check the material being processed is for the correct job run Also check with a supervisor that the job run has not been reprinted Check that program is correct for Valipost Interface Check the material being processed is for the correct job run Check the material being processed is for the correct job run Check all connections Check Valipost is powered on and is working correctly Check that Valipost has the correct database for the job being processed Engineer action if fault persists Inform IT department or production department that a job run has been repeated Check all electrical connections are secure Check serial comms are correctly set up in IMOS and in the Valipost server Inform IT department or production department that a job run has been repeated Inform IT department or production department that a job run has been repeated Check all conn
120. ollers are running freely d Check the sensor values clear and blocked for the hi cap exit sensor e Ensure that the OMR transport belts are driving correctly and that the adjustable collars are securely clamped to the drive shafts a Check the 2 feed clutches are driving correctly and that they are not slipping b Check that the hi cap brakes are not binding c Check that the roller clutches in all the transport rollers are running freely d Check the sensor values clear and blocked for the hi cap exit sensor e Ensure that the OMR transport belts are driving correctly and that the adjustable collars are securely clamped to the drive shafts f Check to ensure that there are enough guide brackets item 7 section 4c 26 and that they are guiding the paper over the chassis bridges a Check the collate hp1 sensor value blocked and clear b Check that the collate drive belts are operating correctly without slip c Check the functionality of the hp1 clutch and brake d Check the sensor values clear and blocked for the hi cap exit sensor e Ensure that the OMR transport belts are driving correctly and that the adjustable collars are securely clamped to the drive shafts f Check to ensure that there are enough guide brackets item 7 section 4c 26 and that they are guiding the paper over the chassis bridges a Check the collate hp1 sensor value blocked and clear b Check that the collate drive belts are operating correctly without
121. on tinue Check value of sensors clear and blocked in Engineer mode Check value of sensors clear and blocked in Engineer mode Check for paper traps for the particular paper being used Ensure that all material has been removed from the unit Check for free movement of all T bearings Test feed clutch feed brake and exit clutch and exit brake for correct operation Check the functionality of the exit clutch and brake Check for free movement of all T bearings Check value of sensors clear and blocked in Engineer mode Check for free movement of all T bearings Test feed clutch feed brake and exit clutch and exit brake for correct operation Remove group s at sheet divert 1 Remove group s at sheet divert 2 Page 52 Error Code 312 313 314 315 316 317 318 319 321 322 Error Message Possible cor rupt group at shuttle Incomplete Alias tables Unexpected document at collate HP1 Unexpected document at collate HP2 Collate pocket too small Too many late divert labels Too many late divert labels received Too few late divert labels received Verification mismatch of marked group s Group ID Verification mismatch Recovery Information Remove group s at shuttle Press Clear and Re start and try again Remove document from collate tray and retry Remove document from collate tray and retry Check document set
122. ons correctly e Run the divert motor in engineer and activate the divert 1 solenoid by hand and by machine control In either case ensure the divert functions easily and that there is not excessive load imparted by the drive shaft against the movement of the divert solenoid a Check the values of the divert entry and divert exit sensors clear and blocked b Check the divert clutch is operating and that it does not bind when off c Check that the divert brake works correctly and does not bind when off Check the program configuration is as required a Check the home magnet is in place and not damaged b Check the functionality of the home reed switch using a spare magnet a Check the value of the insert track index and clock sensors blocked and clear b Check that all the pawls on the belts are in place and that the belts are tight Before suspecting the machine ensure that the program being used is correct for the material being processed and that the marks match those of the calibration sheet Also ensure that the material is within the company specification Re calibrate the scanner and check performance If bad read is still returned a Go to Engineer test mode and check the static performance of the scanner against the calibration sheet b Check that the tacho is working correctly by moving the OMR conveyor belts and watching the light on the OMR board go on and off approximately 1 flash every 2mm d Check that the OMR c
123. onveyor belts are driving correctly and that the drive collars are locked securely to the shaft Page 31 Error Code 168 169 170 Error Message Parity Error at Divert Bin 1 Parity Error at Divert Bin 2 Parity Error at Shuttle Recovery Information Remove forms from Divert Bin 1 and manually correct Remove forms from Divert Bin 2 and manually correct Remove forms from Shuttle Bed and manually correct Operator action if fault persists Check that the marks are aligned with the OMR head Check that the marks are consistently in the same place on consecutive pages Check that the print quality is OK and that no marks are partially printed Check the pitch has not been changed relative to the calibration sheet Carefully clean the scanner lenses ask Technical Support for help in doing this if required Check number of marks for correct parity Check print run is correct Check correct parity Check parity mark is programmed Check correct parity mode off odd even Check that the marks are aligned with the OMR head Check that the marks are consistently in the same place on consecutive pages Check that the print quality is OK and that no marks are partially printed Check the pitch has not been changed relative to the calibration sheet Carefully clean the scanner lenses ask Technical Support for help in doing this if required Check that the marks are aligned with the OMR head Check that the marks
124. or Clean all sensors in the collator using an air duster Check that all envelopes are removed from the wetter closer Clean all sensors in the wetter closer using an air duster Ensure all paper is removed from the turnover eject area Check that the material being processed is the correct size for the job configuration Make sure there are no obstructions on the track or the upstream or downstream tracks Ensure that the shuttle pawls are not blocking the insert track pawls from moving Engineer action if fault persists Check that the track guide motor runs backwards and forwards in engineer mode If track guide motor is struggling to drive the track guide then a Disassemble the track guide mechanism b Check that the slider moves freely up and down the slide shaft c Check that the drive shaft rotates freely in the slide shaft and the brass bush in the slide bracket d Check that the motor rotates freely when not attached to the mechanism a Check that the collate clutches and brakes are not binding b Check all clutches and brakes operate correctly in engineer c Check there are no material catch points related to the documents being processed a Check there are no material catch points related to the documents being processed b Check for free running of the conveyor belts and all the idle rollers on the pressure assembly aluminium extrusion c Check that the drive and idle shaft positions are correct and that the
125. p in doing this Check that the hi cap pressure assembly is securely latched down Clean all Hi Cap sensors with an air duster Clean all feed and transport wheels with a clean cloth and clean water Contact Technical Support Clean all the rollers and belts of the envelope opener path Clean all sensors of the opener path with an air duster Clean all the rollers and belts of the envelope opener path Clean all sensors of the opener path with an air duster Check to ensure that the paper being used is not too distorted If it is then reduce the quantity in the paper trolley until the message disappears Ensure that the trolley side guides are not too tight Engineer action if fault persists Before suspecting the machine ensure that the program being used is correct for the material being processed and that the marks match those of the calibration sheet Also ensure that the material is within the company specification Re calibrate the scanner and check performance If bad sequence is still returned a Go to Engineer test mode and check the static performance of the scanner against the calibration sheet b Check that the tacho is working correctly by moving the OMR conveyor belts and watching the light on the OMR board go on and off approximately 1 flash every 2mm d Check that the OMR conveyor belts are driving correctly and that the drive collars are locked securely to the shaft a Check the value of the hi cap exit sensor
126. pages Check that the print quality is OK and that no marks are partially printed Check the pitch has not been changed relative to the calibration sheet Carefully clean the scanner lenses ask Technical Support for help in doing this if required Check number of marks for correct parity Check print run is correct Check correct parity Check parity mark is programmed Check correct parity mode off odd even Engineer action if fault persists This is a function of stationery and programming a Check that the doubles sensor will return sensible values when calibrated on 80gsm paper b Check that the material being used does not present a solid black print to the doubles detector If so then move the sensor across away from the solid black area c Check that all the drives are functioning correctly and that there is no paper slip a In engineer check that the franker backstop runs freely over its whole range of travel b Ensure that the franker interface is not distorted either by its own support legs or by any part of the franker distortion will cause binding in the backstop mechanism a Check the franker sensor value clear and blocked b Check that the drive out roller set is in contact with the franker eject wheels Before suspecting the machine ensure that the program being used is correct for the material being processed and that the marks match those of the calibration sheet Also ensure that the material is within th
127. ping the aluminium drive wheels on the drive shaft If not then loosen the M4 cap head screws holding the roller shafts and push them closer to the drive wheels then lock the M4 screws to secure Re check the drive of the exit rollers If the folder is making bad folds then a Check the paper is being fed square to the folder from the hi cap or the divert unit b Check the fold plates are square to the fold plate assembly the fold plates can be angled to compensate for small fold errors Too much adjustment will cause bad folding and should be corrected by straightening the feed c Check the squareness to each other of the fold plate fins if one of these is above the others then it will cause bad folds at higher speeds a Check that the fold plate sensor is functioning correctly b Check that the no fold prongs on each fold plate are straight and are passing through the slots provided a Check the clutches of the collate conveyor are not binding on and are free running b Check that the brakes are working correctly c Check the HP1 and HP2 sensor values blocked and clear Page 26 Error Code 143 144 145 146 Error Message Document lost from Collate Hold point 2 Successful OMR calibration Bad OMR calibration Feeder Hybrid Motor failed to achieve speed Recovery Information Remove documents in collator and retry Remove documents in collator and press Start Check correct OMR Calibration
128. processing when the job number on the documents has changed Manually rotate the carriage drive shaft and check for free running of the carriage Clean the shaft and base plate section where carriage support bearings run Check that there are no envelopes located between the opener conveyor HP2 and the flap gripper rollers Manually rotate the flap gripper rollers to eject any envelopes under the insert platform Engineer action if fault persists Inform IT department or production department that a job run has been repeated Inform IT department or production department that a job run has been repeated Inform IT department or production department that a job run has been repeated Advise the customer that their stationery contains more than one job number in the run Check that the motor drives correctly in both directions Check the carriage index and clock sensors are operating correctly Check the functionality of the flap gripper stepper and the flap sensor Check the functionality of HP2 and its free return movement Page 69 Error Code 603 604 605 606 607 608 609 Error Message Envelope Flap Jam Env Side Guide 1 Stall Env Side Guide 2 Stall Env Side Guides Failed to Sync Inclined Envelope Feed Conveyor Stall Job Number Has Changed Job Number Has Changed Recovery Information Remove Jammed Envelope from flap gripper Check remove any envelopes at HP2 by lifti
129. pty Feed Jam Recovery Information Please Autoend the current job and check ALL settings are correct Re calibrate if necessary Please remove documents from card feeder HP1 and HP2 press start to continue Load empty feed station Open feeder cover clear jam re load Feeder and press start to continue Operator action if fault persists Run the calibration process again ensuring that the LVDT plunger moves up and down freely Check the definition of the displayed fault code in the fault message This gives a more detailed description of the fault with the card feeder If the job has been run successfully before check the following operator settings a Clean the feed tyres with a clean cloth and clean water b Check that the side guides are not too tight leave 1 to 2mm each side of the document c Check that the forms are neatly loaded and stacked and that the first form is resting against the feed tyres d Ensure that you have not forced too many forms against the feed tyres and caused the pack to wedge If these are OK then a Check that the separator gap gives a light grip between the feed wheels and the separator stones b Watch the conveyor and check to see that it moves forward c Check that the feed wheels rotate when required If any of these are not true then call the Service Engineer If the job is being run for the first time and the feeder is trying to feed then a Check the program settings
130. r against the calibration sheet b Check that the tacho is working correctly by moving the OMR conveyor belts and watching the light on the OMR board go on and off approximately 1 flash every 2mm c Check that the OMR conveyor belts are driving correctly and that the drive collars are locked securely to the shaft a Check that envelopes leave the machine without the use of the franker b Check the values of the wetter closer exit sensor and the franker sensor clear and blocked See Recovery Information Find the unit with the code 179 error After the error occurs immediately take a trace F3 Capture Trace Capture Ensure that you add suitable notes on the trace after it is taken and send the trace to Technical Support Page 34 Error Code 180 181 182 183 Error Message Flushed documents at shuttle bed Envelope stopped at envelope opener hold point 1 Folder OMR motor stall Folder OMR motor failed to achieve speed Recovery Information Open covers and remove all documents from all shuttle beds Open the envelope opener divert cover and remove envelope from hold point 1 Remove all documents from unit Re load and press Start to continue Press Start to continue If fault persists call Technical Support Operator action if fault persists Check to ensure that envelopes are not damaged before use and that the windows are securely gummed down Ensure side guides are correctly set and
131. r and the handover clock sensor blocked and clear Before making any other check ensure that the document at insert sensor and flap sensor are correct both blocked and clear a Check condition of pawled belts b Check the kicker index sensor blocked and clear Before making any other check ensure that the eject paper sensor is correct both blocked and clear a Check condition of pawled belts b Check the eject index sensor blocked and clear a Check the sensor values blocked and clear of the insert track 1 advanced and the document at insert b Check the starting positions of the insert track 1 handover and kickers to ensure none of them are blocking at the wrong time c If any of the steppers are out of position at the start check the programs being used d Check all 3 stepper index sensors a Check the value of the flap sensor blocked and clear b Check the performance of the flap stepper and the flap stepper clock disc sensor blocked and clear Page 22 Error Code 120 121 122 123 124 125 126 Error Message Document lost at Insert Track Separator mask motor stall Wetter tank empty Hi cap lift motor has stalled Hi cap Trolley out Hi cap empty Thick Double detected Recovery Information Remove jam at insert track Press start to continue If fault persists call Technical Support Re fill wetter tank If problem persists call Technical Support Make sure Trolley is
132. rack Select Call Doubles and restart machine If fault persists check document settings Check Franker Interface is clear Press start to continue Remove envelopes from output conveyor check franker is running restart machine Remove form from Folder OMR Re load and press Start to continue Operator action if fault persists Using the touch screen touch the area of track where the mismatch has occurred Find which documents are out of place and remove further documents until matching is achieved You can remove one document at a time and let the machine cycle once until the next mismatch Keep doing this until the machine brings the matching back together correctly Re calibrate doubles and try again Check to ensure that the doubles sensor is not aligned with solid black print if it is then contact Technical Support for help Clean all feed and transport wheels with a clean cloth and clean water Ensure that the pressure assembly is correctly latched home Clean the doubles sensor using an air duster Ensure that all envelopes are removed from the franker and franker interface Ensure that the franker has not been forced up against the franker interface causing distortion of the metalwork Ensure that the output of the franker is clear Ensure that the envelope conveyor is not blocked Check that the marks are aligned with the OMR head Check that the marks are consistently in the same place on consecutive
133. rator Engineer action if fault persists a Check the free running of the motor over its full range in engineer b Check that the fold plate latched sensor is working If the motor is struggling to move the mechanism dissemble the mechanism and check that a The slider slides freely up and down the slide shaft b The belt is clamped firmly between the slider and the stop plate c The drive shaft rotates freely in the slide shaft and the brass bush in the side of the fold plate d That the motor rotates freely when the fold plate is unlatched Check the free running of the motor over its full range in Engineer If the motor is struggling to move the mechanism dissemble the mechanism and check that a The slider slides freely up and down the slide shaft b The belt is clamped firmly between the slider and the stop plate c The drive shaft rotates freely in the slide shaft and the brass bush in the side of the fold plate d The motor rotates freely when the fold plate is removed from the machine a Check the free running of the motor over its full range in engineer b Check that the fold plate latched sensor is working If the motor is struggling to move the mechanism dissemble the mechanism and check that a The slider slides freely up and down the slide shaft b The belt is clamped firmly between the slider and the stop plate c The drive shaft rotates freely in the slide shaft and the brass bush in the side of the fold plate
134. rator action if fault persists Check that the hi cap pressure roller assembly is properly latched down Clean all hi cap feed and transport rollers with clean water and a clean cloth For an online systems check spring pressures on SOL check HP stops are operating correctly and not sticking Check that the hi cap pressure roller assembly is properly latched down Clean all hi cap feed and transport rollers with clean water and a clean cloth For an online systems check spring pressures on SOL check HP stops are operating correctly and not sticking Check that the hi cap pressure assembly is securely latched down Clean all Hi Cap sensors with an air duster Clean all feed and transport wheels with a clean cloth and clean water For an online systems check spring pressures on SOL check HP stops are operating correctly and not sticking Clean all the OMR folder sensors with an air duster Unlatch the folder OMR slide it back and then re latch it home firmly Engineer action if fault persists a Check the 2 feed clutches are driving correctly and that they are not slipping b Check that the hi cap brakes are not binding c Check that the roller clutches in all the transport rollers are running freely d Check the sensor values clear and blocked for the hi cap exit sensor e Ensure that the OMR transport belts are driving correctly and that the adjustable collars are securely clamped to the drive shafts a Check the 2 feed cl
135. risk Remove forms from Divert Bin 1 and manually correct Operator action if fault persists Check that the marks are aligned with the OMR head Check that the marks are consistently in the same place on consecutive pages Check that the print quality is OK and that no marks are partially printed Check the pitch has not been changed relative to the calibration sheet Carefully clean the scanner lenses ask Technical Support for help in doing this if required Check document widths programmed for this job If problem persists call Technical Support Re calibrate doubles and try again Check to ensure that the doubles sensor is not aligned with solid black print if it is then contact technical support for help Clean all feed and transport wheels with a clean cloth and clean water Ensure that the pressure assembly is correctly latched home Clean the doubles sensor using an air duster Check that the marks are aligned with the OMR head Check that the marks are consistently in the same place on consecutive pages Check that the print quality is OK and that no marks are partially printed Check the pitch has not been changed relative to the calibration sheet Carefully clean the scanner lenses ask Technical Support for help in doing this if required Engineer action if fault persists Before suspecting the machine ensure that the program being used is correct for the material being processed and that the marks match those of t
136. rogram being used is correct for the material being processed and that the marks match those of the calibration sheet Also ensure that the material is within the company specification Re calibrate the scanner and check performance If bad sequence is still returned a Go to engineer test mode and check the static performance of the scanner against the calibration sheet b Check that the tacho is working correctly by moving the OMR conveyor belts and watching the light on the OMR board go on and off approximately 1 flash every 2mm d Check that the OMR conveyor belts are driving correctly and that the drive collars are locked securely to the shaft Page 24 Error Code 132 133 134 135 136 137 Error Message OMR Barcode Bad Group Sequence Unexpected document at OMR Barcode area Hi cap lift motor jitter Envelope lost at opener Envelope lost at Envelope hold point Hi cap overrun Recovery Information Check document order Clear forms and re start FLT_HICAPJITTER FLT_OPENERLOST FLT_ENVHPLOST Check paper stack Operator action if fault persists Check that the marks are aligned with the OMR head Check that the marks are consistently in the same place on consecutive pages Check that the print quality is OK and that no marks are partially printed Check the pitch has not been changed relative to the calibration sheet Carefully clean the scanner lenses ask Technical Support for hel
137. rrectly this may unexpectedly block the turnover eject sensor so ensure fingers are set correctly a Check the drive to the feeder interface b Check that the feed brake is not binding on c Check that the feed clutch is operating correctly d Check the shuttle stepper is operating correctly e Check the shuttle index sensor value blocked and clear a Check the shuttle bed sensor value blocked and clear note that this sensor is forced to a 13mA emitter current and should have a pot value of zero a Check the shuttle bed sensor value blocked and clear note that this sensor is forced to a 13mA emitter current and should have a pot value of zero b Check the track top and bottom sensor values clear and blocked c Check the operation of the shuttle stepper d Check to ensure that shuttle belts are not too loose a Check the shuttle bed sensor value clear and blocked b check the functionality of the 3 off adjustable shuttle guide springs Check the blocked and clear values of the folder exit and the shuttle bed sensor in engineer mode Check HP before the shuttle depends on hardware fitted is working correctly clutches not binding brakes working Sol working correctly Connect a multimeter to the test points on the dual LVDT PCB and check the voltage setting for each device is 1 5V Page 12 Error Error Message Code 60 Document failed to arrive at OMR Barcode area 61 Document jam OMR Bar code area 62 Document
138. rsists Check to ensure that no pieces of paper are left in any position on the machine local to the printer Check to ensure that envelopes are free to move through the printer and that there are no obstructions to free movement Check the printer head height relative the pack thickness Check job settings Press clear and restart to clear message Check job settings Press clear and restart to clear message Check to ensure there is nothing obstructing the closure of the printer cover Engineer action if fault persists Check the printer exit sensor is operating correctly going blocked and clear and that the final exit sensor after the franker is operating correctly Check the printer entry sensor is operating correctly Check to see that the transport system is working correctly and that the belts are not worn See Operator Advice See Operator Advice Check the functionality of the cover switch Check to ensure the external relay in the head of the DS 1XXxX is connected and operating correctly Page 58 Error Code 409 410 411 412 413 414 Error Message Printer Buffer Time out General Printer Error Envelope Printer No Reply Unable to Purge Printer as HP Blocked Purged Envelope Successful Too Many Successive Address Not Found in Database Recovery Information Check printer is not in fault condition Check Envelope printer for exact error code Correct fault before
139. rt Bin 1 Recovery Information Remove documents from the unit and continue Check Document grouping is correct Remove Short on Long guides from all stations Fit or adjust Short on Long guides to X mm Press Start to continue Remove all filled envelopes from the VS and manually correct Remove all filled envelopes from the VS and manually correct Remove all filled envelopes from the VS and manually correct Remove all filled envelopes from the VS and manually correct Remove group from Divert 2 and manually correct Operator action if fault persists Ensure all documents are removed from the unit and the covers are opened and closed Check configuration and document details are correct Check track guides move freely after removing short on long guides Check configuration and document details are correct Check shuttle pawls move freely and do not catch on the short on long guides Check the configuration is correct for more than one short on long station Check configuration for Jog is correct Check adjustments for VS to the inserter are OK Check to see if the VS entry tapes are correctly adjusted Check configuration for Jog is correct Check adjustments for VS to the inserter are OK Check to see if the VS entry tapes are correctly adjusted Check configuration for Jog is correct Check adjustments for VS to the inserter are OK Check to see if the VS entry tapes are correctly ad
140. rt lifts and falls freely and that envelopes pass freely along the through path b Check value of eject sensor clear and blocked c Check conveyor belts are running freely Page 42 Error Code 230 231 232 233 Error Message Envelope jam at Output Divert 2 Eject Envelope jam at Output Divert 3 Eject Envelope failed to arrive at Output Divert 1 Divert Envelope failed to arrive at Output Divert 2 Divert Recovery Information Clear jam Press Start to continue Clear jam Press Start to continue Clear jam Press Start to continue Clear jam Press Start to continue Operator action if fault persists Ensure program is correct for envelope size being used Clean divert sensor on angled slope using an air duster Ensure divert conveyor is clear of material directly below the diverter Ensure program is correct for envelope size being used Clean divert sensor on angled slope using an air duster Ensure divert conveyor is clear of material directly below the diverter Ensure program is correct for envelope size being used Clean divert sensor on angled slope using an air duster Ensure divert conveyor is clear of material directly below the diverter or if a mail bag is fitted ensure bin bag is not full or that mail bag is not restricting the free fall of the envelope Ensure program is correct for envelope size being used Clean divert sensor on angled slope using an air duster
141. rusion b Check the alignment between the collate conveyor side guides and the collate pocket side guides c Try reducing the number of balls in the collate back stop d Increase the collate pocket clearance from 2mm to 4mm e Increase the collate pocket depth in 1mm steps f Check the eject sensor value blocked and clear a Check collate stepper index sensor b Check drive pulley is locked to motor shaft c Check free running of collate pocket pawled belts Check sensors for calibrated levels Check functionality and free movement of front stop Check sensors for calibrated levels Check exit clutch and brake for functionality and free movement a Check condition of pawled belts b Check that motor pulley is securely locked to the motor shaft c Check the insert track index sensor blocked and clear and the insert track clock sensor blocked and clear d Run the stepper in Engineer screen and check the returned number of clocks forward and back These should be equal in both directions to within 2 clocks e While still in Engineer stepper test add resistance to the pawls and watch the change in returned clocks This should give an indication of the strength of the stepper Page 15 Error Error Message Code 81 Shuttle stepper has stalled 83 Insert finger stepper has stalled 84 Turnover eject stepper has stalled 85 Kicker stepper has stalled Recovery Information Press start to continue Remove document
142. rvisor or the IT department for support Contact a supervisor or the IT department for support Contact a supervisor or the IT department for support Engineer action if fault persists Inform IT department or production department that a job run has been repeated Inform IT department or production department that a job run is not valid Inform IT department or production department that a job run is corrupt Test network and server status If network or server status is at fault contact your IT department for support Test network and server status If network or server status is at fault contact your IT department for support Test network and server status If network or server status is at fault contact your IT department for support Page 79 Error Code 1028 1029 1030 1031 1040 1041 Error Message Data Received Piece Removed Data Received Piece Added Data Received Piece Removed Double Data Received Piece Added Double Create Connection Failure No Response from AIMS Close Connection Failure Recovery Information See AIMS and or IMOS error log file for more details If fault persists contact NTL IPSS See AIMS and or IMOS error log file for more details If fault persists contact NTL IPSS See AIMS and or IMOS error log file for more details If fault persists contact NTL IPSS See AIMS and or IMOS error log file for more details If fault persists contact NTL IPSS
143. s and check the AIMS Error log for more details Load documents into feeder Press Start to continue If fault continues call Technical Support Remove document and check label setup is correct Operator action if fault persists Check reader setup in output divert unit Check barcode configuration and job programming for correct setup Check reader setup in output divert unit Check barcode configuration and job programming for correct setup Check the camera or reader setup is correct Adjust dis tance from leading edge to label for QX Hawk Adjust trig ger delay for camera reading system to ensure the label is in the ROI Contact a supervisor or the IT department for support One of the cascading feeders is empty re load and press start to continue If fault continues call Technical Support Check label set up is correct and the number of characters in the label is correct Check reader set up alignment Engineer action if fault persists Check reader set up and consistency of read Go to read rate test to confirm setup Check data logs for reason of failure Check reader set up and consistency of read Go to read rate test to confirm setup Check data logs for reason of failure Check all connections between the reader and unit 0 are in place and operating correctly Test network and server status If network or server status is at fault contact your IT department for support See Operator
144. s away from the solid black area c Check that all the drives are functioning correctly and that there is no paper slip Page 23 Error Code 127 128 129 130 131 Error Message Thin Double detected Possibly calibrated on double thickness Length Double detected Check Separator Gap Hi Cap Stack Flag not seen Potential Doubles Error Detected Collate OMR Sequence Error Recovery Information Re calibrate doubles Check that envelopes filled since last doubles calibration do not contain doubles Check separator settings Lower sheet feeder tray Remove any par tially fed documents Press Run to re try Please check all documents on the unit Correct any faults found Press Run to Continue Remove all documents from unit Manually correct the current set and any following sets Operator action if fault persists Re calibrate doubles and try again Check to ensure that the doubles sensor is not aligned with solid black print if it is then contact Technical Support for help Clean all feed and transport wheels with a clean cloth and clean water Ensure that the pressure assembly is correctly latched home Clean the doubles sensor using an air duster Re calibrate doubles and try again Clean all feed and transport wheels with a clean cloth and clean water Ensure that the pressure assembly is correctly latched home Clean all sensors using an air duster Clean sensors on hi cap l
145. s been left in the exit of the cutter or on the cutter interface Feed a form from both tractors of the cutter to ensure operation is correct Check to ensure that no material has been left in the exit of the cutter or on the cutter interface Feed a form from both tractors of the cutter to ensure operation is correct Check to ensure that no material has been left in the exit of the cutter or on the cutter interface Feed a form from both tractors of the cutter to ensure operation is correct Check to ensure that no material has been left in the exit of the cutter or on the cutter interface Feed a form from both tractors of the cutter to ensure operation is correct Check to ensure that no material has been left in the exit of the cutter or on the cutter interface Feed a form from both tractors of the cutter to ensure operation is correct Engineer action if fault persists Check that Valipost has the correct database for the job be ing processed Check that Valipost has the correct database for the job being processed Check that Valipost has the correct database for the job being processed Check the drive clutch and brake of the cutter interface operate correctly Check the interface sensor operates correctly Check the drive clutch and brake of the cutter interface operate correctly Check the interface sensor operates correctly Check the drive clutch and brake of the cutter interface operate correctly Check the interface s
146. s correct If fault persist contact NTL IPSS for more detailed recovery information Press Clear and Restart and Retry Check reader fitted Press Clear and restart and retry Remove group from Collate Pocket and manually correct Remove group from Divert 1 and manually correct Remove group from Divert 2 and manually correct Operator action if fault persists Check cable connections to the reader are not damaged or loose Check all connections and the configuration is correct Check physical setting of reader is to specification and that the label can be read by a hand held reader Check the reader is connected to the correct output J1 J2 Press Clear and restart to try to re establish communications with the reader Ensure scanner is correctly aligned to marks and calibrated for OMR Ensure marks are to company barcode or OMR specifications Ensure scanner is correctly aligned to marks and calibrated for OMR Ensure marks are to company barcode or OMR specifications Ensure scanner is correctly aligned to marks and calibrated for OMR Ensure marks are to company barcode or OMR specifications Engineer action if fault persists Check power is being applied to scanner Use the reader setup screen to see if communication is being established with the reader Test the reader on a different unit to ensure connections are not at fault Check the reader is connected to the correct output J1 J2 Che
147. s working correctly Check SOL HP2 sensor is working correctly a Check the folder exit sensor b Check the drive to the fold rollers is correct and that the motor pulley is securely locked to the motor shaft c Check that the No fold beams are pivoting freely d Check that the fold plates run freely over their full length of travel including deflecting the no fold beams if sluggish check the slide mechanisms are clean and free from dirt a Check the folder exit sensor b Check the drive to the fold rollers is correct and that the motor pulley is securely locked to the motor shaft c Check that the No fold beams are pivoting freely d Check that the fold plates run freely over their full length of travel including deflecting the no fold beams if sluggish check the slide mechanisms are clean and free from dirt a Check that the hi cap clutches are free running and not binding b Check that the hi cap brakes are operating correctly c Check that the pressure roller carrier in the hi cap is correctly latched down and that the springs G1026a are correctly located If a diverter is fitted a Check that the clutch is free running and not binding on b Check that the brake is functioning correctly c Check that the drive belt to the clutch is not over tight note that the belt tensioner should only be used to remove slack and not to apply any tension to the belt Page 5 Error Code 18 19 20 21 22 Error Messag
148. screw for each spring assembly Check that program matches paper being cut by guillotine Clean all sensors using an air duster Ensure all springs are in contact with conveyor belts with a light pressure Increase or decrease tension where necessary by adjusting the M4 cap head screw for each spring assembly Check that program matches paper being cut by guillotine Check adjustment of side guides is not too tight Clean all sensors using an air duster Ensure all springs are in contact with conveyor belts with a light pressure Increase tension where necessary by tightening the M4 cap head screw for each spring assembly Check that program matches paper being cut by guillotine Clean the S O L HP1 and HP2 sensors using an air duster Check spring pressure under each spring Ensure that all documents and damaged material is removed from the output divert units Press start to continue Engineer action if fault persists See Recovery Information Ensure number of characters in label is set correctly Ensure data logging parameters are correct If variable length labels are being used different number of characters in each label switch security check to none Re check operator action before assuming there is a fault a Check that both solenoid stops are working correctly b Check values of all 3 paper sensors clear and blocked c Check conveyor belts are not slipping Re check operator action before assuming
149. sed with this job Ensure the wetter assembly is correctly positioned for the envelope flap being processed Ensure there are no obstructions in the wetter bits of removed envelopes Ensure that the inserts are correctly inserted into envelopes If not then make adjustments at the insert area Engineer action if fault persists a Check the pressure between the flap gripper rollers and the needle bearing on the insert plate b Check that the flap gripper stepper is driving correctly Remove all material from the insert platform Check the blocked and clear sensor values of the flap sensor Clean the flap sensor with an air duster if required Check re move any partially fed envelopes from HP2 lift the insert top plate to gain access If envelop path is clear and job is complete Press clear and re start to clear all flushing mes sages a Check that the turnover motor and drive are functioning properly b Ensure that the belts are running true and not tracking off c Check that the kicker belts are not rubbing on the insert plate and that there is at least 2mm clearance as the kicker belts reach the end of the insert plate d Check the turnover index sensor clear and blocked e Check the turnover eject sensor clear and blocked a Check the turnover eject sensor clear and blocked b Check the turnover index sensor clear and blocked c Check the turnover eject stepper operation d Check for obstructions in the wetter a C
150. sheet and alignment of reader Press Start to continue If fault persists call Technical Support Operator action if fault persists Clean the collate HP1 and HP2 sensors using an air duster See Recovery Information Check that the marks are aligned with the OMR head Check that the print quality is OK and that no marks are partially printed Carefully clean the scanner lenses ask Technical Support for help in doing this if required Ensure that all paper has been removed from the unit Engineer action if fault persists a Check the clutches of the collate conveyor are not binding on and are free running b Check that the brakes are working correctly c Check the HP1 and HP2 sensor values blocked and clear See Recovery Information Before suspecting the machine ensure that the program being used is correct for the material being processed and that the marks match those of the calibration sheet Also ensure that the material is within the company specification Re calibrate the scanner and check performance If the scanner will not read then a Go to Engineer test mode and check the static performance of the scanner against the calibration sheet b Check that the trigger light on the OMR board flashes momentarily when the calibration sheet passes to the OMR unit c Check that the tacho is working by moving the OMR conveyor belts and watching the light on the OMR board go on and off d Check that the OMR conveyor belts ar
151. ssed a Check that there are no obstructions in the fold plates b Rotate the fold motor by hand and ensure that the fold rollers rotate freely a Check the motor pulley b Check the motor drive belt c Check that the turnover belts do not track off during running and jam in the metalwork Page 19 Error Code 103 104 105 106 107 Error Message Fold plate 1 is stalled Fold plate 2 is stalled Fold plate 3 is stalled Insert platform backstop is stalled Separator motor has stalled Recovery Information Check fold plate 1 3 assembly is correctly in position Press start to continue Check that fold plate 2 is correctly latched Press start to continue Check fold plate 1 3 assembly is correctly in position Press start to continue Ensure there are no documents on the Insert platform Press start to continue If fault persists call Technical Support Operator action if fault persists Check that the fold plate 1 3 assembly is correctly latched home Blow out any paper dust in the fold plate mechanism using an air duster Blow out any paper dust in the fold plate mechanism using an air duster Check that the fold plate 1 3 assembly is correctly latched home Blow out any paper dust in the fold plate mechanism using an air duster Ensure the head is correctly latched down Ensure there are no obstructions on the insert platform Ensure all paper is removed from around the sepa
152. start to continue Remove document from Shuttle Bed Press start to continue Remove document from Shuttle Bed Press start to continue Press start to continue Remove insert from shuttle Press start to continue Check the contents of last envelope processed Re calibrate the thickness checker Operator action if fault persists Clean the turnover eject sensor and flap position sensor with an air duster Check all document settings are correct Check that the document size is correct for the job configuration Clean the shuttle bed sensor using an air duster Clean the shuttle bed sensor using an air duster Check that the document size is correct for the job configuration Clean the shuttle bed and track top and bottom sensors using an air duster Check to ensure that the document size is correct for the job configuration Adjust the shuttle pressure springs 3 off to increase the resistance to document movement Clean the shuttle bed and fold exit sensor with an air duster Check all document fold settings are correct Check to ensure that the carriage holding the thickness checking devices is correctly latched down and that both devices are moving up and down freely Engineer action if fault persists Check the blocked and clear values for the turnover eject and flap sensors Check the pressure is correct for flap gripper rollers Check all document settings are correct If any material is not inserted co
153. sts Check sensors are clean and those that are accessible are correctly seated in sensor housings Carry out a manual calibration of the unit Check cutter has a valid program set for the program being selected from the configuration Check to ensure that no pieces of paper are left in any position on the machine local to the printer Replace the faulty power supply as soon as possible to ensure the normal operation is maintained Replace the faulty power supply as soon as possible to ensure the normal operation is maintained Replace the faulty power supply as soon as possible to ensure the normal operation is maintained Engineer action if fault persists Check all sensors are correctly seated in housings Find the sensor that is out of top limit and check electrical connection for correct contact and damage Replace sensor if fault cannot be cured Check electrical connections for unit Check dip switches are correctly set Check processor address Check unit hardware and setup is correct Program job 12 in the cutter create a new job in the inserter using program 12 Check to see if job is selected Job 12 is the default job Check the printer exit sensor is operating correctly going blocked and clear Unplug the power supply from the bus bar apply power to the power supply and use a meter to test the 8V rail Check power distribution sensor leads are correctly located Check LEDs are lit Check bus bar fuses
154. sure that the divert assembly opened with the black handle is securely latched down Ensure there are no obstructions on the cover of the opener divert Always ensure that the divert assembly opened with the black handle is securely latched down Engineer action if fault persists Check serial connections are in place If fault persists take a trace from the main machine and check responses from card feeder NA a Check the opener entry opener flap and envelope feeder HP1 sensor values clear and blocked Run the hybrid motor for the envelope feed and ensure that all drives are running freely and can be loaded without causing slippage b Check that the opener extrusion is pivoting freely and that the return spring is in place a Check the opener entry opener flap and envelope feeder HP1 sensor values clear and blocked b Run the hybrid motor for the envelope feed and ensure that all drives are running freely and can be loaded without causing slippage c Check that the opener extrusion is pivoting freely and that the return spring is in place a Clean the rollers which drive the unopened envelope out of the divert cover b Ensure that there are no obstructions to the rejected envelope leaving the reject slot in the divert cover process an envelope round the divert by hand c Check the functionality of the reject solenoid d Check that the extrusions pull down when the solenoid is activated so that they do not catch on th
155. t guide for options e Check 80gsm separator setting re calibrate if necessary f Check free running of separator shield and that it indexes correctly to furthest forward position fully shielded g Check that the pick up clutch operates correctly a Check the deskew and HP1 sensor values clear and blocked in engineer b Check the feed clutch is driving properly c Check that the feed brake is operating correctly and not binding d Check that the roller clutches in the pick up wheels are freely rotating and not binding Page 4 Error Code 12 13 14 15 16 17 Error Message Feeder has stream fed Document lost from feeder Calibration document not loaded in single online Document has not left fold rollers Jam between feeder and folder Unexpected document at output of folder Recovery Information Check separator gap and shield position Re load and press start to continue Remove document from the feeder Press start to continue Load calibration document into the SOL feeder at HP2 Press start to continue Open fold plate 1 3 assembly and remove documents from rollers Close fold plate assembly and press start to continue Check for document at output of feeder and fold plate 1 3 assembly Remove document and press start to continue Remove document from output of Folder and or Shuttle Bed Press start to continue Operator action if fault persists a Decrease
156. t slot in the divert cover process an envelope round the divert by hand c Check the functionality of the reject solenoid d Check that the extrusions pull down when the solenoid is activated so that they do not catch on the transport belts and do not cause the envelopes to catch on their leading edges a Clean the rollers which drive the unopened envelope out of the divert cover b Ensure that there are no obstructions to the rejected envelope leaving the reject slot in the divert cover process an envelope round the divert by hand c Check the functionality of the reject solenoid d Check that the extrusions pull down when the solenoid is activated so that they do not catch on the transport belts and do not cause the envelopes to catch on their leading edges a Check the flap sensor value blocked and clear b Check that the solenoid at HP2 is operating correctly b Check that the stop is rotating freely d Check that the stop goes down below the bed by at least 1mm e Check the pressure between the flap gripper rollers and the needle bearing on the insert plate is tight a Check the flap sensor value blocked and clear b Check the pressure between the flap gripper rollers and the needle bearing on the insert plate is tight c Check that the flap gripper stepper is driving correctly Page 9 Error Code 38 39 40 41 42 Error Message Envelope has overrun or been removed from insert area Flushe
157. t the bed height e Ensure that the closer guide spring item 29 section 4a 18 is in the correct position a Check the eject and closer sensor clear and blocked values b Ensure that the routing of the sensor wires is as far away as possible from the motor to prevent noise a Check the closer and eject sensor values clear and blocked b Check for obstructions in the wetter c Check for free running of all the pressure rollers on the roller carrier extrusion d Check that an even pressure is achieved between every roller on the roller carrier and the drive belts use the adjustable collars that support the wetter bed to adjust the bed height e Ensure that the closer guide spring item 29 section 4a 18 is in the correct position f Check that the output devices are correctly positioned and are functioning correctly to take the envelopes away Advise the customer of label characters for changing machine control Page 11 Error Code 48 50 51 52 53 54 55 Error Message Turnover Unex pected Document has not arrived at Shuttle Bed Shuttle cannot resync as it is blocked by a document Document jam at Shuttle Bed Document has overrun the Shuttle Bed or been removed Shuttle Unex pected Thickness Checker Calibration Failure Recovery Information Remove filled enve lope from turnover Press start to continue Remove document from feeder interface folder output Press
158. there is a fault a Check that both solenoid stops are working correctly b Check values of all 3 paper sensors clear and blocked Re check operator action before assuming there is a fault a Check that both solenoid stops are working correctly b Check values of all 3 paper sensors clear and blocked c Check conveyor belts are not slipping Check the HP1 and HP2 sensor values blocked and clear Check pressure of guide springs Check that the solenoid stops are functioning correctly a Check that the drive train from the motor is free running by rotating the motor shaft by hand and that all belts are properly on pulleys b Run the hybrid motor in Engineer mode Page 41 Error Code 222 223 224 225 226 227 228 229 Error Message Output Divert Hybrid motor failed to achieve speed Output Divert 1 back stop stalled Output Divert 2 back stop stalled Output Divert 3 back stop stalled Envelope failed to arrive at Output Divert 1 Eject Envelope failed to arrive at Output Divert 2 Eject Envelope failed to arrive at Output Divert 3 Eject Envelope jam at Output Divert 1 Eject Recovery Information Press Start to continue If fault persists call Technical Support Press Start to continue If fault persists call Technical Support Press Start to continue If fault persists call Technical Support Press Start to continue If fault persists call Technical Support
159. tion of pawled belts b Check that motor pulley is securely locked to the motor shaft c Check the kicker index sensor blocked and clear and the kicker clock sensor blocked and clear d Run the stepper in Engineer screen and check the returned number of clocks forward and back These should be equal in both directions to within 2 clocks e While still in Engineer stepper test add resistance to the pawls and watch the change in returned clocks This should give an indication of the strength of the stepper f Check that the kicker belt pawls are not hitting any part of the kicker assembly or the insert platform g Check that at the front end the kicker pawls are at least 2mm above the insert platform Page 16 Error Code 86 87 88 90 Error Message Handover Stepper has stalled Collate eject stepper stalled The envelope has not arrived or left the insert area correctly Shuttle stepper failed to index Recovery Information Remove document from insert platform and Unit 1 transfer If fault persists call Technical Support Remove envelope from insert platform and any partially fed envelope on conveyor Press start to continue Remove documents from Shuttle Bed and retry If fault persists call Technical Support Operator action if fault persists Check that there are no obstructions to the handover stepper Check that the handover belts are not damaged and that all the pawls are in place Check t
160. to NTL for Analysis Capture a trace manually Send this to NTL for Analysis Capture a trace manually Send this to NTL for Analysis Check the cutter for correct setup of the sync sensor to the syncronisation marks on each page Check reader setup in cutter Check the cutter for correct setup Check serial comms for cutter Check sensor settings remain consistent Any sensor changing value significantly between calibrations should be replaced Page 56 Error Code 395 396 397 399 400 401 402 Error Message Sensors Dirty Multiple Sensors Failed to Calibrate Invalid Cutter programme selected Envelope not arrived at printer exit The 8 volt supply has failed The 36 volt supply has failed The 8 volts and 36 volts has failed Recovery Information Clean Sensors then re calibrate Check all wiring clean sensors check for paper blocking then re calibrate Check configuration is correct and that the cutter has a valid programme selected Remove filled envelopes from the output area If required clear the DEP buffer Press run to continue Replace the faulty power supply as soon as possible to ensure the normal operation is maintained Replace the faulty power supply as soon as possible to ensure the normal operation is maintained Replace the faulty power supply as soon as possible to ensure the normal operation is maintained Operator action if fault persi
161. troubleshooting information Reader data is not associated with the correct document data record Remove all docs press clear amp re start and try again See operator troubleshooting information If variable length labels are being used set the number of characters in the label to the max used and switch security check to none Page 54 Error Code 333 334 335 336 337 338 Error Message Output Control has Stopped the Output Conveyor Form Jammed in Folder OMR 1 Folder OMR 2 lost Too Many Forms in Divert Bin 1 Too Many Forms in Divert Bin 2 Unexpected Document Fold OMR Entry Sensor Recovery Information Conveyor control mode has been set to stop machine by Er ror Ink mark or Omr Barcode Sort enve lopes on the Con veyor and press Start to continue Remove form from Folder OMR 1 Deskew sensor Check docs at Fold OMR HP and Shuttle Oversized group has been diverted Check settings are correct for max fold and too many forms action Oversized group has been diverted Check settings are correct for max fold and too many forms action Remove Documents from Fold OMR and Press Go to Continue Operator action if fault persists Check output configuration options the conveyor control mode is set to stop machine or the machine is set to stop when an error group arrives at the conveyor or the machine is set to stop when an envelope is ink marked
162. ust if necessary b Ensure back stop is adjusting to the same position every time c Check value of divert sensor clear and blocked d Check solenoid adjustments are correct to provide sufficient lift to allow envelope cleanly into divert e Check divert conveyor pulses correctly and that conveyor belts do not slip f If a mail bag is fitted ensure that the bag does not restrict free fall of the envelope note that for a mail bag you can increase the back stop setting by up to 15mm above the nominal setting as the accuracy is far less important than for a divert conveyor Page 44 Error Code 237 238 239 240 241 242 Error Message Envelope jam at Output Divert 3 Divert Batch complete at Output Conveyor Batch complete at Output Divert 1 Batch complete at Output Divert 2 Batch complete at Output Divert 3 Ink marked batch complete Recovery Information Clear jam Press Start to continue Remove batch Zero red counter Press Start to continue Remove batch Zero red counter Press Start to continue Remove batch Zero red counter Press Start to continue Remove batch Zero red counter Press Start to continue Remove batch Zero red counter Press Start to continue Operator action if fault persists Ensure program is correct for envelope size being used Clean divert sensor on angled slope using an air duster Ensure divert conveyor is clear of material directly be
163. utches are driving correctly and that they are not slipping b Check that the hi cap brakes are not binding c Check that the roller clutches in all the transport rollers are running freely d Check the sensor values clear and blocked for the hi cap exit sensor e Ensure that the OMR transport belts are driving correctly and that the adjustable collars are securely clamped to the drive shafts f Check to ensure that there are enough guide brackets item 7 section 4c 26 and that they are guiding the paper over the chassis bridges a Check the value of the hi cap exit sensor b Check that all the clutches are freely rotating and not binding on c Check that all the hi cap brakes are working correctly d Check all the hi cap roller clutches are free running and not binding a Check the values of the OMR folder entry and exit sensors clear and blocked b Check the conveyor clutch is operating and that it does not bind when off c Check that the conveyor brake works correctly and does not bind when off a Check the home magnet is in place and not damaged b Check the functionality of the home reed switch using a spare magnet Page 36 Error Code 189 190 191 192 193 Error Message OMR mismatch Double sample limit Franker backstop stalled Output conveyor blocked Folder OMR parity error Recovery Information Remove forms from Shuttle Bed or Track to correctly match next group on the t
164. velope is closing sealing correctly Also that all config settings are correct for the envelope fold Ensure all material is removed from the VS input area Ensure all material is removed from the VS input area Ensure all material is removed from the VS input area Check the Vertical Stacker input sensor is not faulty If Fault persists then replace the sensor Engineer action if fault persists Check that there are no obstructions to the VS input path Check that the VS input belts are not damaged and that all the pawls are in place Check that the pawls on the belts are not being obstructed spring guide tapes on the VS input Clean the paper sensor with an air duster See operator Recovery information If fault persists call Technical Support See operator Recovery information If fault persists call Technical Support Adjust the Vertical stacker input guide springs to guide the envelope into the vs input pocket Too much restriction will prevent the envelope from clearing the sensor correctly Also ensure the VS height is correct Check that the VS side guide motor runs backwards and forwards in engineer mode If the backstop motor is struggling to drive the turnover backstop then a Disassemble the backstop mechanism b Check that the slider moves freely up and down the slide shaft c Check that the drive shaft rotates freely in the slide shaft and the brass bush in the turnover chassis d Check that the motor rotates
165. y Jammed Documents and check for any obvious obstructions Remove any Jammed Documents and check for any obvious obstructions Check and Remove any documents in the unit Operator action if fault persists Open the exit conveyor lid and remove all documents If necessary pull the accumulator back on its slides and remove any documents from the pocket before the exit conveyor Ensure the exit conveyor lid is latched home correctly Open the exit conveyor lid and remove all documents If necessary pull the accumulator back on its slides and remove any documents from the pocket before the exit conveyor Ensure the exit conveyor lid is latched home correctly Open the exit conveyor lid and remove all documents If necessary pull the accumulator back on its slides and remove any documents from the pocket before the exit conveyor Ensure the exit conveyor lid is latched home correctly Open the exit conveyor lid and remove all documents If necessary pull the accumulator back on its slides and remove any documents from the pocket before the exit conveyor Ensure the exit conveyor lid is latched home correctly Move the accumulator back on its slide rails and ensure that the FFPD is completely clear of all documents Move the collate stepper by hand and ensure it moves freely through a complete belt cycle to detect if there is still any paper left in the unit Move the accumulator back on its slide rails and ensure that the FFPD is
166. your IT department for support Page 78 Error Code 1022 1023 1024 1025 1026 1027 Error Message Data Received Duplicate Document ID Data Received Invalid Job Number Data Received Invalid Doc Number Data Received Invalid Data Data Received Invalid Page Number Data Received Invalid Process Type Recovery Information Document ID read has already been processed Remove ALL documents from the unit and manually correct documents Job ID has no Database on AIMS See AIMS and or IMOS error log file for more details If fault persists contact NTL IPSS Piece ID read is not in the Database See AIMS and or IMOS error log file for more details If fault persists contact NTL IPSS See AIMS and or IMOS error log file for more details If fault persists contact NTL IPSS See AIMS and or IMOS error log file for more details If fault persists contact NTL IPSS See AIMS and or IMOS error log file for more details If fault persists contact NTL IPSS Operator action if fault persists Check the material being processed is for the correct job run Also check with a supervisor that the job run has not been reprinted Check the material being processed is for the correct job run Check to ensure that job has been copied to the AIMS server Check the material being processed is for the correct job run Also check with a supervisor that the job run has not been reprinted Contact a supe
167. your IT department for support Test network and server status If network or server status is at fault contact your IT department for support Test network and server status If network or server status is at fault contact your IT department for support Page 81 Error Code 1053 1054 1055 1056 1057 Error Message Connection Already Open Process Type is Not Valid Create Connection Request Not Received Invalid Number of Arguments in the Data Packet Invalid Argument in the Data Packet Recovery Information Check all connections and settings are correct See AIMS and or IMOS error log file for more details If fault persists contact NTLIPSS Check all connections and settings are correct See AIMS and or IMOS error log file for more details If fault persists contact NTLIPSS Check all connections and settings are correct See AIMS and or IMOS error log file for more details If fault persists contact NTLIPSS Check all connections and settings are correct See AIMS and or IMOS error log file for more details If fault persists contact NTLIPSS Check all connections and settings are correct See AIMS and or IMOS error log file for more details If fault persists contact NTLIPSS Operator action if fault persists Contact a supervisor or the IT department for support Contact a supervisor or the IT department for support Contact a supervisor or the IT department for support Co

DS-1000/1200 Advanced Troubleshooting Guide

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