Sie sind auf Seite 1von 376

Service Manual

075.1

Revision: rev. 1.0 - 12/2009


Date: December 2009

rev. 1.0 - 12/2009

075.1

075.1

ii

Service Manual

rev. 1.0 - 12/2009

Service Manual

075.1

Table of Contents
1

This manual ................................................................................... 1-1


1.1
1.2
1.3

Health, safety and environment ..................................................... 2-1


2.1
2.2
2.3

Abbreviations ..................................................................................... 1-1


Terminology ....................................................................................... 1-1
Typographical conventions ................................................................... 1-2

Safety instructions ..............................................................................


2.1.1
General ..................................................................................
2.1.2
Electrical safety .......................................................................
Symbols on the machine ......................................................................
End of life ..........................................................................................

2-1
2-1
2-1
2-1
2-1

General description ........................................................................ 3-1


3.1
3.2
3.3
3.4

3.5

3.6

The system ........................................................................................ 3-1


Denominations ................................................................................... 3-1
Paper flow .......................................................................................... 3-2
Process description .............................................................................. 3-2
3.4.1
Document feeding ................................................................... 3-7
3.4.2
Document transport ................................................................. 3-8
3.4.3
Collating the document set ....................................................... 3-8
3.4.4
Document folding .................................................................. 3-11
3.4.5
Envelope feeding ................................................................... 3-12
3.4.7
Envelope exit process ............................................................ 3-14
Electronics ....................................................................................... 3-15
3.5.1
PCB functions ....................................................................... 3-15
3.5.2
Schematic overview ............................................................... 3-16
3.5.3
Connection with PC (Concorde application) ............................... 3-17
3.5.4
The ID-tag ........................................................................... 3-17
3.5.5
Software package compatibility check ...................................... 3-19
Optional features .............................................................................. 3-19
3.6.1
Reading ............................................................................... 3-19
3.6.2
Flex reading ......................................................................... 3-19
3.6.3
High capacity BRE maxiFeeder .............................................. 3-19
3.6.4
Insertn Frank .................................................................... 3-20
3.6.5
Online services ..................................................................... 3-20
3.6.6
High Capacity Vertical Stacker ................................................. 3-20
3.6.7
Side exit .............................................................................. 3-20
3.6.8
Mail Piece Production Control (MPPC) ....................................... 3-20

rev. 1.0 - 12/2009

iii

075.1

User interface ................................................................................. 4-1


4.1
4.2
4.3

Operator menus ................................................................................. 4-1


Job and supervisor menus .................................................................... 4-1
Service menu ..................................................................................... 4-1
4.3.1
System settings ...................................................................... 4-2
4.3.2
Job settings ............................................................................ 4-3
4.3.3
Service tests .......................................................................... 4-4
4.3.4
Service counters ..................................................................... 4-7
4.3.5
Reading: OMR ........................................................................ 4-8
4.3.6
Reading: BCR ....................................................................... 4-11
4.3.7
Diagnostics .......................................................................... 4-14
4.3.8
Online service ....................................................................... 4-14
4.3.9
Remove blockage .................................................................. 4-15
4.3.10 Sealing on franking machine ................................................... 4-15

The 075.1 ........................................................................................ 5-1


5.1
5.2

5.3

5.4

iv

Service Manual

Transport, storage and installation ........................................................ 5-1


5.1.1
Transport ............................................................................... 5-1
5.1.2
Unpacking, installation and storage ........................................... 5-1
Mechanical description ......................................................................... 5-6
5.2.1
General ................................................................................. 5-6
5.2.2
(Dis)assembly - Covers and plates ............................................ 5-7
5.2.3
(Dis)assembly - Electrical components ..................................... 5-11
5.2.4
(Dis)assembly - Feeder modules and vertical transport right-hand 5-14
5.2.5
(Dis)assembly - Feeders ........................................................ 5-19
5.2.6
(Dis)assembly - Vertical transport ........................................... 5-30
5.2.7
(Dis)assembly - Collating area ................................................ 5-31
5.2.8
(Dis)assembly - Folder ........................................................... 5-34
5.2.9
(Dis)assembly - Main drive mechanism inserter ......................... 5-47
5.2.10 (Dis)assembly - Envelope hopper ............................................ 5-55
5.2.11 (Dis)assembly - Upper unit ..................................................... 5-62
5.2.12 (Dis)assembly - Envelope transport ......................................... 5-69
5.2.13 (Dis)assembly - Envelope sealing and ejection .......................... 5-70
5.2.14 (Dis)assembly - Sensors ........................................................ 5-71
5.2.15 Adjustment .......................................................................... 5-88
Electrical description ......................................................................... 5-99
5.3.1
PCBs ................................................................................... 5-99
5.3.2
Display board ..................................................................... 5-100
5.3.3
Keyboard ........................................................................... 5-101
5.3.4
Motor relay board ................................................................ 5-102
5.3.5
Connection board ................................................................ 5-103
5.3.6
Communication board (optional) ........................................... 5-105
5.3.7
Main board ......................................................................... 5-109
5.3.8
ID-tag (2994504Z) .............................................................. 5-115
Maintenance .................................................................................. 5-116
5.4.1
Preventive maintenance ....................................................... 5-116
5.4.2
160k Service visit ................................................................ 5-117
5.4.3
500k Service visit ................................................................ 5-118

rev. 1.0 - 12/2009

Service Manual

Fault finding ................................................................................... 6-1


6.1
6.2
6.3

6.4

075.1

Resolve problems remotely .................................................................. 6-1


Troubleshooting Online Services ............................................................ 6-2
Error handling inserter ......................................................................... 6-2
6.3.1
Battery errors (BAT) ................................................................ 6-4
6.3.2
MPPC errors (CL) ..................................................................... 6-4
6.3.3
Closer errors (CLS) .................................................................. 6-4
6.3.4
Communication errors (COM) .................................................... 6-5
6.3.5
Collator errors (CT) ................................................................. 6-6
6.3.6
DFC errors (DC) ...................................................................... 6-6
6.3.7
Document feeder errors (DF) .................................................... 6-7
6.3.8
Dongle errors (DG) .................................................................. 6-7
6.3.9
Envelope hopper errors (EH) ..................................................... 6-8
6.3.10 Envelope open errors (EOP) ...................................................... 6-8
6.3.11 Folder errors (FOL) .................................................................. 6-9
6.3.12 Insert errors (INS) .................................................................. 6-9
6.3.13 Job errors (JOB) .................................................................... 6-10
6.3.14 Level detector errors (LD) ...................................................... 6-11
6.3.15 License errors (LIC) ............................................................... 6-11
6.3.16 Motor errors (M) ................................................................... 6-12
6.3.17 Modem errors (MOD) ............................................................. 6-12
6.3.18 Online service errors (OLS) ..................................................... 6-14
6.3.19 Reading head errors (OR) ....................................................... 6-15
6.3.20 Photocell errors (Pxx) ............................................................ 6-15
6.3.21 PCB errors (PBx) ................................................................... 6-18
6.3.22 Pulse disc errors (PD) ............................................................ 6-18
6.3.23 Production control errors (PRC) ............................................... 6-19
6.3.24 Reading errors (RE) ............................................................... 6-19
6.3.25 Machine state errors (SM) ...................................................... 6-22
6.3.26 Stacker errors (STK) .............................................................. 6-22
6.3.27 Switches errors (SW) ............................................................. 6-23
6.3.28 System errors (SYS) .............................................................. 6-23
6.3.29 Transport errors (TR) ............................................................. 6-24
Error handling franking machine ......................................................... 6-25
6.4.1
Communication errors (COM) .................................................. 6-26
6.4.2
External errors (EX) ............................................................... 6-26
6.4.3
Insertn Frank errors (INF) ................................................... 6-27
6.4.4
License errors (LIC) ............................................................... 6-34
6.4.5
Cover switch errors (SW) ....................................................... 6-34

Upgrading and installing accessories ............................................. 7-1

7.1
7.2
7.3
7.4
7.5
7.6
7.7

Reading (barcode en OMR) ...................................................................


MaxiFeeder ......................................................................................
Insertn Frank ..................................................................................
Side exit ............................................................................................
High Capacity Vertical Stacker ..............................................................
Mail Piece Production Control (MPPC) .....................................................
Online services ...................................................................................
7.7.1
Preparations ...........................................................................
7.7.2
Connect the system .................................................................

rev. 1.0 - 12/2009

7-1
7-1
7-1
7-1
7-1
7-1
7-1
7-1
7-2

075.1

Technical specifications .................................................................. 8-1


8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11

8.12

8.13

vi

Service Manual

Machine specifications ......................................................................... 8-1


Documents ........................................................................................ 8-3
Envelopes .......................................................................................... 8-5
Capacity feeders and exit options .......................................................... 8-6
Fold types .......................................................................................... 8-7
Processing speed ................................................................................ 8-7
Configuration dimensions ..................................................................... 8-8
System operation control .................................................................... 8-8
Other general specifications ................................................................. 8-9
Quality .............................................................................................. 8-9
Reading (Optical Mark Recognition) ....................................................... 8-9
8.11.1 Concept ................................................................................. 8-9
8.11.2 Format of the marks ................................................................ 8-9
8.11.3 Reading head location .............................................................. 8-9
8.11.4 Options .................................................................................. 8-9
Reading (Barcode) .............................................................................. 8-9
8.12.1 Concept ................................................................................. 8-9
8.12.2 Format of the code .................................................................. 8-9
8.12.3 Reading head location .............................................................. 8-9
8.12.4 Options .................................................................................. 8-9
Product customization per country / organization .................................. 8-10

rev. 1.0 - 12/2009

Service Manual

075.1

Illustrated parts list ....................................................................... 9-1


9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
9.13
9.14
9.15
9.16
9.17
9.18
9.19
9.20
9.21
9.22
9.23
9.24
9.25
9.26
9.27
9.28
9.29
9.30
9.31
9.32
9.33
9.34
9.35
9.36
9.37
9.38

Covers, frames, and external parts 1/3 .................................................. 9-2


Covers, frames, and external parts 2/3 .................................................. 9-6
Covers, frames, and external parts 3/3 .................................................. 9-8
Envelope hopper 1/2 ......................................................................... 9-10
Envelope hopper 2/2 ......................................................................... 9-12
Envelope separation .......................................................................... 9-14
Lower envelope track 1/2 ................................................................... 9-16
Lower envelope track 2/2 ................................................................... 9-20
Insert table and upper envelope track .................................................. 9-22
Insert and eject mechanism ............................................................... 9-26
Moistening unit ................................................................................. 9-28
Envelope closing mechanism .............................................................. 9-30
Main drive mechanism ....................................................................... 9-32
Feeder/Folder driving mechanism ........................................................ 9-34
Envelope track driving mechanism 1/2 ................................................. 9-36
Envelope track driving mechanism 2/2 ................................................. 9-38
Document feeder unit (automatic) ....................................................... 9-40
Document feeder unit - special 1/2 ...................................................... 9-44
Document feeder unit - special 2/2 ...................................................... 9-46
Document feeder trays ...................................................................... 9-48
Vertical track (base) .......................................................................... 9-50
Vertical track (loc) ............................................................................ 9-52
Collating unit (upper) ........................................................................ 9-54
Collating unit (lower) and power supply ............................................... 9-58
Folder unit (base) ............................................................................. 9-62
Folder unit (loc) 1/4 .......................................................................... 9-64
Folder unit (loc) 2/4 .......................................................................... 9-66
Folder unit (loc) 3/4 .......................................................................... 9-68
Folder unit (loc) 4/4 .......................................................................... 9-70
Electrical components ........................................................................ 9-72
High capacity feeder 1/4 .................................................................... 9-74
High capacity feeder 2/4 .................................................................... 9-76
High capacity feeder 3/4 .................................................................... 9-78
High capacity feeder 4/4 .................................................................... 9-80
High capacity feeder tray ................................................................... 9-82
Side exit 1/3 .................................................................................... 9-84
Side exit 2/3 .................................................................................... 9-86
Side exit 3/3 .................................................................................... 9-88

rev. 1.0 - 12/2009

vii

075.1

10

Appendix ....................................................................................... 10-1


10.1
10.2
10.3

10.4
10.5

10.6
10.7
10.8

viii

Service Manual

Recommended spare parts ................................................................. 10-1


Electrical diagrams ............................................................................ 10-6
Product coding for CRM ................................................................... 10-32
10.3.1 Failure symptoms ................................................................ 10-32
10.3.2 Module .............................................................................. 10-32
10.3.3 Failure origins ..................................................................... 10-33
Checklist training operator ............................................................... 10-39
High Capacity Vertical Stacker .......................................................... 10-43
10.5.1 Process description .............................................................. 10-43
10.5.2 (Dis)assembly - High Capacity Vertical Stacker ....................... 10-44
10.5.3 Preventive maintenance ....................................................... 10-54
10.5.4 Troubleshooting .................................................................. 10-54
10.5.5 Electrical diagram HCVS-1 (2825913J) ................................... 10-55
10.5.6 Parts list ............................................................................ 10-56
10.5.7 Recommended spare parts HCVS-1 ....................................... 10-65
10.5.8 Specifications High Capacity Vertical Stacker .......................... 10-66
Total view electronics sheet 1/3 ........................................................ 10-67
Total view electronics sheet 2/3 ........................................................ 10-68
Total view electronics sheet 3/3 ........................................................ 10-69

rev. 1.0 - 12/2009

Service Manual
1

This manual

1.1

075.1

Abbreviations

Abbrev. Explanation

Abbrev.

Explanation

BRE

Business Reply Envelope

ISIS

Interface Standard Inserting Systems

CCW

Counter Clockwise

LH

Left Hand

CW

Clockwise

MPPC

Mail Piece Production Control

DFC

Double Feed Control

MS

Mailing System

DS

Document System

OLS

OnLine Services

FM

Franking Machine

OMR

Optical Mark Recognition

GUI

Graphical User Interface

PCB

Printed Circuit Board

HMI

Human Machine Interface

RH

Right hand

I2C

Inter-Integrated Circuit

SCS

Serial Communication System

INF

insertn Frank

UI

User Interface

1.2

Terminology

Term

Description

Double Feed
Control (DFC)

Double Feed Control measures the thickness of a sheet to check if the


inserting system does not accidentally take more sheets than intended. DFC
sensors exist on feeders (double sheet detection). DFCs on the inserting
systems perform relative measurements, which means that they need a
cycle to 'learn' the thickness of a sheet.
Also the length of the document is measured so partly overlapping sheets
will be detected.

Leading

Situation in which the top of the sheet is closest to the separation unit in a
document feeder.

Pane Cycle

The various documents of a set are fed from the feeders in such a way that
these documents are partly overlapping each other. This pane-like
overlapping ensures a higher throughput.

Sequential Cycle

Documents are transported along the vertical track without touching each
other. Only after joining the set in the making they do touch each other.

Shunting

The partially completed set in the collator is moved from the collator area
in the direction of the fold unit (short shunt) or into the fold unit (long
shunt). See 3.4.3 Collating the document set on page 3-8.

Trailing

Situation in which the bottom of the sheet is closest to the separation unit
in a document feeder.

rev. 1.0 - 12/2009

1-1

075.1

1.3

Service Manual

Typographical conventions
Warning
This symbol identifies situations where improper use of the machine can result in
personal injury or permanent/catastrophic damage to the machine.
Warning
This symbol identifies situations in which electrical hazard exists.

Note
A note gives additional relevant information.

1-2

rev. 1.0 - 12/2009

Service Manual
2

Health, safety and environment

2.1

Safety instructions

2.1.1

075.1

General

This machine must be operated by competent personnel.


The manufacturer accepts no responsibility for accidents or injuries caused by operation by
incompetent personnel.
Covers may only be opened by skilled persons, who know the risks involved.
For safety reasons, the machine will not function with opened covers.
Keep away long hair, fingers, jewelry, etc. from rotating and moving objects of the system.
Switch off the system at the end of the day.

2.1.2

2.2

Electrical safety

The power connection must be easily accessible, preferably close to the machine.
For safety reasons it is essential that the machine is connected to a socket outlet with
protective earth connection.
Over-current protection in the equipment also relies on the branch circuit protection (max.
20 A).
Disconnect the machine from the power supply when it is not in use for a longer time.
Potential hazard may exist to electronic hardware in conditions with static electricity. It is
advised that, when handling electronic parts, an earth connected wrist band is used in order
to be permanently discharged from static electricity.

Symbols on the machine


Warning
This symbol identifies situations where improper use of the machine can result in
personal injury or permanent/catastrophic damage to the machine.

2.3

End of life

The objectives of the European Community's environment policy are, in particular, to preserve,
protect and improve the quality of the environment, protect human health and utilise natural
resources prudently and rationally. That policy is based on the precautionary principle and
principles that preventive action should be taken, that environmental damage should as a
priority be rectified at source.
Separate collection of waste is the precondition to ensure reuse and recycling of waste that is
generated at the disposal of electrical or electronical equipment and is necessary to achieve the
chosen level of protection of human health and the environment in the European Community.
More particularly, certain materials and components of waste electrical and electronical
equipment needs selective treatment as their injudicious handling or disposing of on or into land,
water or air would represent a major threat to the environment and human health.

rev. 1.0 - 12/2009

2-1

075.1

Service Manual

In order to facilitate collection and treatment separated from normal domestic waste, electrical
and electronical equipment is marked with the following logo:
Do not mix with normal domestic waste
Please use the subjoined return or
collection system dedicated to electrical
and electronical waste.

Equipment produced after August 13,


2005.
Not only are you by law not allowed to dispose of the waste equipment via other waste-streams,
but we encourage you to actively contribute to the success of such collection and to the common
good and better quality of life of present and future generations.
For more information on the correct disposal of this product please contact your local dealer.

2-2

rev. 1.0 - 12/2009

Service Manual
3

General description

3.1

075.1

The system

The 075.1 feeds, folds and inserts documents into envelopes and then seals and stacks the
envelopes.
The system is equipped with a variety of special features as programmable jobs, loadn Go,
flexFeed, double feed control, hopper swap, multifeed, daily mail, powerFold, and automatic
collator stop positions.

3.2

Denominations

E
A

H
I

T
A
B
C
D
E
F
G
H
I
J

catch tray
envelope slide
display with operating buttons
upper unit
locking hand grip upper unit
document feeder tray
collator arm
collating area
power inlet, power switch,
RS232 connector / USB / modem
handles for clearing stoppages

rev. 1.0 - 12/2009

J L K J

K
L
M
N
O
P
Q
R
S

sensors
bellows
unlocking handle for rollers envelope track
water reservoir
side cover (opened)
ruler
thumb wheel for side guide adjustment
side guides envelope hopper
handle for separation adjustment

Envelope support bracket

3-1

075.1

3.3

Service Manual

Paper flow

2
5
3
6
4

The documents are vertically transported from the document feeder(s) (1) to the collator (2).
When the required documents are collected, the document pile is transported horizontally to the
document folder (3). After folding, the documents are inserted into an envelope by the inserter
(5). Finally, the envelope is sealed and transported to the envelope receiving tray.

3.4

Process description

The processing of documents by the system can be divided into a number of distinct sequential
partial processes. These processes will be discussed in some more detail:

Document feeding

Document transport

Collating the document set

Document folding

Envelope feeding

Inserting process

Envelope exit process


The figure on the next page shows a schematic overview of the process. All mechanical items
that are strictly necessary to explain the process are projected on the left-hand side of the
machine. This implies that not all auxiliary mechanical items (such as gears and belts) are
shown.
See Section 5.2 Mechanical description and Section 9 Illustrated parts list for more details
on the mechanics.

3-2

rev. 1.0 - 12/2009

rev. 1.0 - 12/2009

MS2

PD1

PH4

RX

TX

19

22

23

20

21

PH5

TX

RX

24

25

CL8

So3

So4

18

17

26

So2

15

16

10

TX
PH1

RX

13

TX

RX

14

11

So1

9a

PH3

RX

12

PH2

TX

PD2

31

27

28

29

30

34

33

32

CL6/7

PD3
39

35

36

37

38

M2

41

40

PH7

CL4

77

78

TX

RX

45

TX

46

CL5

CL1

63

64

TX
TX
DFC1

70

71

DFC2

TX

RX

PH6

44

61

PH9

RX

68

PH10

RX

75

PH11

42

43

62

CL2

69

RX

76

CL3

MS3

DFC3

MS1

47

PH8
TX

M1

PD4

65

66

72

73

79

80

48

67

74

81

49

50

51
52

FE1

FE2

FE3

53
54

56
55

57

58

59

60

Service Manual
075.1

3-3

075.1

Service Manual

Rollers
No.

Description

Feed roller. Activated by the envelope track clutch CL8.

Separation roller.

3, 5, 7

Counter rollers for 4, 6 and 8. These rollers can be moved by the release handle in case
of a paper jam in the envelope track.

4, 6, 8

Driven envelope transport rollers. Activated by the envelope track clutch CL8.

9, 12

Counter rollers for 10, 11. These rollers can be moved by the release handle in case of
a paper jam in the envelope track.

9a

Friction brake.

10

Driven envelope transport roller (flap opening stage). Activated by the envelope track
clutch CL8.

11

Driven envelope transport roller (flap opening stage). Activated by the envelope track
clutch CL8.

13

Lower insert roller.

14

Upper insert roller (in the upper unit).

15

Lower first ejection roller. On the axle at the LH side of the machine the LH hand knob
is mounted. On this axle at the RH side of the machine the main pulley is mounted.

16

Upper first ejection roller (in the upper unit). Lowered by the action of the insert table
solenoid So2.

17

Lower second ejection roller. In this area the moistening brushes are located.

18

Upper second ejection roller (in the upper unit).

19

Driven sealing track roller. On the axle at the RH side of the machine the pulse disc PD1
(monitored by slotted photocell SPH1) is mounted.

20

Driven sealing track roller.

21

Counter roller for 22 (in the upper unit).

22

Lower sealing roller. A gear on the axle (on the RH side of the machine) provides via an
intermediate gear the mechanical interface to all the driven parts in the upper unit (14,
16, 24, 26). Directly driven by M2.

23

Upper sealing roller.

24

Lower reverse roller (in the upper unit).

25

Upper reverse roller (in the lower unit). Lowered by the action of the sealing solenoid
So3.

26

Drive rollers for future use.

27

Lower fold roller for second fold table.

28

Upper fold roller for second fold table. In upper unit.

35

Lower fold roller for first fold table.

36

Upper fold roller for first fold table. In upper unit.

3-4

rev. 1.0 - 12/2009

Service Manual

075.1

No.

Description

42

Lower fold input roller. On this axle on the RH side the folding forward clutch CL4 is
mounted. This clutch drives 42, 43, 35, 36, 27 and 28. Operational during the fold
process and during the first stage of a long shunt.

43

Upper fold input roller.

44

Counter roller of 45 (in the upper unit).

45

Driven vertical transport axle. On this axle the folding reverse clutch CL5 is mounted
(at the RH side of the machine). This clutch drives 42, 43, 35, 36, 27 and 28 in the
reverse direction during the second stage of a long shunt.

46, 50, 53, 56,


60

Collator rollers driven (either forward or reverse) by the collator motor M1. In collator
arm.

47, 48, 49, 52,


54, 55, 58

Free running collator rollers.

61

Driven vertical transport axle. On this axle feeder 1 (lower) clutch CL1 is mounted (at
the LH side of the machine). This clutch drives 63, 65 (only in feeder with manual
separation), 66 and 67.

62

Counter rollers for 61 (in upper unit).

63

Driven output rollers.

64

Counter rollers for 63.

65

Lower separation roller. Turns CW in feeder with manual separation.

66

Feed axle with upper separation roller.

67

Paper puller axle with two rubber rollers.

68

Driven vertical transport axle. On this axle feeder 2 (middle) clutch CL2 is mounted (at
the LH side of the machine). This clutch drives 70, 72 (only in feeder with manual
separation), 73 and 74.

69

Counter rollers for 68 (in upper unit).

70

Driven output rollers.

71

Counter rollers for 70.

72

Lower separation roller. Turns CW in feeder with manual separation.

73

Feed axle with upper separation roller.

74

Paper puller axle with two rubber rollers.

75

Driven vertical transport axle. On this axle feeder 3 (upper) clutch CL3 is mounted (at
the LH side of the machine). This clutch drives 77, 79 (only in feeder with manual
separation), 80 and 81.

76

Counter rollers for 75 (in upper unit).

77

Driven output rollers.

rev. 1.0 - 12/2009

3-5

075.1

Service Manual

No.

Description

78

Counter rollers for 77.

79

Lower separation roller. Turns CW in feeder with manual separation.

80

Feed axle with upper separation roller.

81

Paper puller axle with two rubber rollers.

Photocells
No.

Description

PH1

Envelope track cell

PH2

Flap cell

PH3

Insert table cell

PH4

Exit cell

PH5

Closer cell

PH6

Folder entry cell

PH7

Vertical track cell

PH8

Collating area cell

PH9

Feeder cell

PH10

Feeder cell

PH11

Feeder cell

Clutches
No.

Description

CL1

Feeder clutch. Drives 61, 63, 65 (only in feeder with manual separation), 66 and 67.

CL2

Feeder clutch. Drives 68, 70, 72 (only in feeder with manual separation), 73 and 74.

CL3

Feeder clutch. Drives 75, 77, 79 (only in feeder with manual separation), 80 and 81.

CL4

Fold forward clutch. Used during a fold cycle and in the first stage of a long shunt.

CL5

Fold reverse clutch. Used in the second stage of a long shunt.

CL6

First fold table clutch. Drives 37.

CL7

Second fold table clutch. Drives 29.

CL8

Envelope track clutch. Mounted on clutch shaft, at the RH side of the machine. On this
shaft two gears take care for the mechanical interface between the permanently M2
driven subsystem and the envelope track subsystem. CL8 drives 1, 4, 6, 8, 10 and 11.

3-6

rev. 1.0 - 12/2009

Service Manual

075.1

Solenoids
No.

Description

So1

Finger solenoid. Moves the fingers into the envelope when the envelope is on the insert
table.

So2

Insert table solenoid. Moves the ejection roller 16.

So3

Sealing solenoid. Moves roller 25 to transport the envelop to the sealing rollers.

So4

Brush solenoid. Lowers the brush to moisten the envelope flap.

3.4.1

Document feeding
DFC3
FE3

RX
PH11

78

77

80

81

79

TX

CL3

FE2

RX

RX

TX
TX
FE1

RX

TX

Rollers 79 - 81 separate the document for feeder 3.


Rollers 77 and 78 exit this document to the vertical track. DFC unit 3 measures the
thickness.
Photocell PH11 monitors the document.

Clutch CL3, driven by main motor M2, drives feeder 3.

rev. 1.0 - 12/2009

3-7

075.1

3.4.2

Service Manual

Document transport

FE3

RX

TX

CL3
76

FE2

75

RX

PH7

RX

69

TX
TX

FE1

68

CL2
RX
PH9
TX
62

CL1

61

CL5
44

45

M1

TX
RX
TX
12

27

34

35

Depending on the number of documents to be delivered by each feeder there are two ways in
which documents can be transported along the vertical track: pane cycle and sequential cycle.

Pane Cycle:

The various documents of a set are fed from the feeders in such a way
that these documents are partly overlapping each other. This pane-like
overlapping ensures a higher throughput.

Sequential Cycle: Documents are transported along the vertical track without touching
each other.

When reading is on the sequential cycle is used.

The vertical track consists of one driven roller per feeder (75, 68, 61), plus one driven roller
in the lower vertical track (45).

The driven rollers have their counterparts in rollers 76, 69, 62 and 44.

If the OMR option is installed, the document transport is monitored by the reading head
photocell (PH7). This monitoring is necessary to establish the reading window.
3.4.3

Collating the document set

The following rules apply to the way in which a set is composed (collated):

The highest active feeder is processed first, the lowest active feeder last. This is
independent of the fold type.

3-8

rev. 1.0 - 12/2009

Service Manual

075.1

If a feeder adds two or more documents to a set (multi-feeding), these documents are first
processed.
PH10

RX

70

72

TX
TX
FE1

RX

TX

PD4
CL5
44

M1

45
46

43

48

RX
TX

50

PH8
TX

49

53

51
52

56
54

55

57

59

60

58

47

42
PH6
CL4

The collating area consists of a set of rollers (46, 50, 53, 56 and 60) that can be driven in
both directions by the collator motor (M1).
In the reverse direction of the collator motor documents are fed into the collator area. In
the forward direction they are moved out.
Collating area photocell (PH8) monitors the entry of the paper into the collator area (not the
leaving of paper!).
The documents are aligned against the relevant automatic document stoppers (51, 57 or
59).

Before a sheet is added to the set, the set moves out of the collator to prevent collision of the
document against the set. When the document is added to the set the set moves back into the
collator. The moving into and out of the collator is called shunting. The system can perform a
long shunt or a short shunt. This depends on the mode selection (see System output on
page 4-3).

rev. 1.0 - 12/2009

3-9

075.1

Service Manual

Short shunt (mode 2)

1
2
3
4

PH8 detects a document in the document transport. The transport stops.


M1 runs in the forward direction: the partially completed set is moved over a short distance
to the fold table.
The document transport starts again and moves the document into the collator. M1 runs in
reverse direction and moves the set back into the collator.
The document moves over the set until it is aligned with the set against the paper stop.

Mode 2 focuses on minimal necessary paper displacement. This implies a higher processing
speed. However there is longer paper contact between the new entering document and the
partially completed set.
Long shunt (mode 1)

1
2
3

PH8 detects a document in the document transport. The transport stops.


M1 runs in the forward direction and CL4 is activated: the partially completed set is moved
into the fold table.
The document transport starts again. M1 runs in reverse direction and CL5 is activated.

3-10

rev. 1.0 - 12/2009

Service Manual

075.1

The document and the set move together into the collator until they are aligned against the
paper stop.

Mode 1 takes more time, but the paper-to-paper contact occurs over shorter distances.
When the set is complete M1 (forward direction) and CL4 are activated and the set is moved into
the fold unit.
3.4.4

Document folding
TX
PD3

31

39

CL6/7
PD2
38

30

40
29

TX

28

14

32
33

37
43

36

TX

13
RX

27

34

35

41

42
PH6
CL4

RX
RX
TX

TX

M2

The paper of a completed set leaves the collator area. This is detected by the folder entry
photocell (PH6).

3.4.4.1 First fold

The fold input rollers (42 and 43) transport the paper to the first fold table. The flap (41)
moves up. Paper that enters the first fold table will be directed in upward direction.

At the appropriate time, the flap (41) moves back and the fold plate (40) moves forward.
This is the first fold.

Directly after the fold has been made, the fold plate (40) returns to its rest position. The
movement of the fold plate (40) and the flap (41) is controlled by the first fold table clutch
(CL6). The clutch drives the curve gear (37). The axle for the curve gear also carries the
brake disc (38). Slotted photocell (SPH3) monitors the status of the curve gear.

The 360 degrees fold cycle of the brake disk consists of a 120 degrees part (flap upwards)
and a 240 degrees path (flap downwards plus karate action of 40). The brake disc is
mechanically loaded by a positioning lever and a torsion spring. The hinge axle (39) also
carries the lever for the actuator of flap 41. In this way all movements related to the first
fold table are synchronized.
3.4.4.2 Second fold

After leaving the fold rollers (35 and 36), the paper enters the second fold table. The flap
(34) moves up. Paper that enters the second fold table will be directed in upward direction.

The paper guide (33) also moves up. This guide is necessary in the second fold table to
retain the fold that has been made in the first fold table.

The paper is limited to a small area between the paper guide (33) and a fixed vertical guide
plate (not shown in the figure, but to the left of 33).

At the appropriate time the flap (34) moves back and both the fold plate (32) and the guide
plate (33) move forward. This is the second fold.

rev. 1.0 - 12/2009

3-11

075.1

Service Manual

Directly after the fold has been made, the fold plate (32) returns to its rest position. The
movement of the fold plate (32), the paper guide (33) and the flap (34) is controlled by the
second fold table clutch (CL7). The clutch drives the curve gear (29). The axle for the curve
gear also carries the brake disc (30). The slotted photocell (SPH4) monitors the status of
the curve gear.
The 360 degrees fold cycle of the brake disk consists of a 120 degrees part (flap and paper
guide upwards) and a 240 degrees path (flap and paper guide downwards plus karate
action of 32). The brake disc is mechanically loaded by a positioning lever and a torsion
spring. The hinge axle (31) also carries the lever for the actuator of flap 34. In this way all
movements related to the second fold table are synchronized.

Finally the paper leaves the fold unit on its way (transported by 27 plus 28 and 13 plus 14) to
the insert table.
The timing of the fold plate movement is based on the detection of the paper by the folder entry
photocell PH6, on machine parameters and on operational fold parameters.
3.4.5

Envelope feeding
TX

RX
TX

RX

TX

12
RX

11
RX

PH2

6
9
7

TX

10

8
2

9a

RX

CL8

TX

5
PH1

All the rollers for this process stage (1, 4, 6, 8, 10 and 11) are engaged to the main drive
by the envelope track clutch (CL8). During the document and insert stage these rollers are
disengaged.
The feed and separation rollers (1 and 2) separate an envelope from the stack in the hopper.
The envelope is transported via three pairs of transport rollers (3 - 8). The envelope track
photocell (PH1) detects the leading and trailing edge of the envelope.
The envelope then passes the flap rollers (9 and 10).
The combined action of the flap scraper and the lower linear speed of the flap rollers (9 to
12) compared with the speed of rollers 3 to 8, results in some buckling and the opening of
the envelope.
The flap is the trailing part of the envelope passing the flap rollers and the flap photocell
(PH2).
Pulse measurements (measured via slotted photocell SPH1) during the presence of the
envelope under the photocells (PH1 and PH2) provide information on:
The length of the not yet opened envelope
The length of the opened envelope

3-12

rev. 1.0 - 12/2009

Service Manual

075.1

The time at which the envelope transport is suddenly stopped with the envelope on the
insert table
The sudden stop is the result of disengaging by the envelope track clutch (CL8) and the
friction brake (9a). The envelope flap now is fixed between two rollers (11 and 12).
In the final ejecting, sealing and exiting stage the driven rollers are engaged once again to
release the envelope (held between 11 and 12) and to feed a new envelope to the insert
table.

3.4.6

Inserting process

So1
TX
14
12

13

RX

11

PH3

RX

9a

RX
TX

TX

Once the envelope is on the insert table, the fingers solenoid (So1) is activated. The fingers
are moved forward into the envelope. The envelope stays in place, it is fixed between the
two rollers (11 and 12).
Now the document set is inserted. The set leaves the fold unit (transported by rollers 27
plus 28 and by 13 plus 14), is detected by the insert table photocell (PH3) and passes below
the fingers before it enters the envelope.
When the insert table photocell (PH3) detects the trailing edge of the set, the set is inserted.

rev. 1.0 - 12/2009

3-13

075.1

3.4.7

Service Manual

Envelope exit process


TX

So3
PH5
RX

23

25

TX

MS2

24

22

26

21

RX
PH4

So4

PD1

So2

20

TX
16

14

18

19

12

13

15

RX

11

17

PH3

RX
CL8

RX
TX

TX

The clutch (CL8) is activated to release the flap (roller 11 and 12) and to feed a new
envelope to the insert table. The insert table solenoid (So2) moves the ejection roller (16).
Now the envelope is ejected from the insert table. So2 is deactivated after the complete
passage of the filled envelope.
The filled envelope passes rollers 17 and 18. If sealing is on, So4 is activated and lowers
the moistening brushes. The envelope passes the sealing track rollers (19 and 20) and the
lower sealing roller (22) plus its counter roller (21).
Now the photocell (PH5) is triggered. The upper reverse roller (25) is held up by a spring.
A certain time after triggering PH5 the sealing solenoid (So3) is activated. The envelope is
between the upper and lower reverse rollers. So3 lowers reverse roller 25. Given the turning
direction of the lower reverse roller (24), the transport direction of the envelope is abruptly
changed.
The envelope is transported through the sealing rollers 22 and 23. After passing the sealing
rollers the envelope exits the system.
The exit photocell (PH4) monitors the passing envelope.

3-14

rev. 1.0 - 12/2009

Service Manual

3.5

Electronics

3.5.1

075.1

PCB functions

The functions of the PCBs from the schematic overviews can be described as follows:
Board name

Function

Display board

Converts received data into understandable data for the display

Key board

Contains the start and stop buttons

Motor relay board

Turns the motor on and off

4a

Connection board

Provides connection to USB, RS232 and the phone line (see note)

4b

Modem board
(optional)

Converts digital data (from the processor) into analogue data (for
external communication) and the other way around

Communication board
(optional)

Controls the franking interface and external communication

Main PCB

Operates the device and controls the user interface

ID-tag

Contains information (serial number, encrypted machine options,


encrypted total counter)

Note
The regular connection board only provides connection to USB. The expanded connection board
also provides connection to RS232 and the phone line.
See Section 5.3 Electrical description for the location of the PCBs in the system.

rev. 1.0 - 12/2009

3-15

075.1

3.5.2

Service Manual

Schematic overview

The electronics and the wiring between the boards in the 075.1 can be summarized in a
schematic overview.
For a device without communication board:

Host
075.1
Display board

Keyboard

USB cable

Connection board
regular

USB device
Main PCB

Switch mode
Power supply

ID Tag

Motor relay
board

24Vdc

100/115,230V ac
For a device with communication board:

Host

075.1

Phone
Display board

Keyboard
Host
USB
device
Main PCB

ID Tag

Communication
board

RS232
(INF)

USB
cable

Connection board
Expanded

serial
Switch mode
Power supply
24Vdc

Modem
board

Motor relay
board

100/115,230V ac

3-16

rev. 1.0 - 12/2009

Service Manual

3.5.3

075.1

Connection with PC (Concorde application)

If you want to upgrade the inserter software or backup information from the inserter, the
inserter can be connected to a PC. Special software has to be installed on the PC to enable
communication between the USB port of the PC and the machine. This application is called
Concorde.
The

primary functions of Concorde are:


To flash software packages in a complete system (with multiple boards)
To flash new software directly on a board (factory flash)
To backup inserter information and export it to XML format
To restore information into the inserter from a previous backup

The Concorde application has been developed in such a way so that it requires minimal upgrades
in the future. For more information, please see the online help contained in the Concorde
application.
3.5.4

The ID-tag

Each time the 075.1 is started, the presence of the ID-tag is checked.

If the ID-tag is not present, all software controlled options are switched off.

rev. 1.0 - 12/2009

3-17

075.1

Service Manual

If the ID-tag is present, its serial number is compared to the serial number in the FRAM
(refer to the following schedule) and the options are read out.
Start up: Read ID-TAG and FRAM
OK
Serial
number ID-TAG
= Serial number
FRAM

Yes

ID-TAG
count=FRAM
count

No

No

Define
latest
counter

Yes

TAG
correct

Copy
ID-TAG Counter to
FRAM

FRAM
correct
Copy
FRAM Counter to
ID-TAG

System blockage error


Call Service

System deblockage in
service menu
OK
Has the
main board been
replaced only?

Yes4

Synchronize
ID-TAG
Counter to FRAM

Copy
Serial number
ID-TAG to FRAM

Yes5

Set Counter
manually (ID-TAG
and FRAM)

Copy
Serial number
ID-TAG to FRAM

No
Have
the ID-TAG
and the main board
been replaced?

END

In this schedule, number 1 to 5 can be described by:


1

Normal situation

If either FRAM or TAG has been disconnected, the latest counter can be used.

Replacement of PCB or replacement of both the ID-Tag and PCB.

PCB replacement (Tag OK).

PCB and ID-Tag replacement (new ID-Tag)

Note: if incorrect Tag is installed, software controlled options and connectivity will
not function correctly.

3-18

rev. 1.0 - 12/2009

Service Manual

The

075.1

following information is stored on the ID-tag:


Serial number of the machine.
Encrypted machine options.
Total insert counter (kept up to date when the 075.1 is running).

3.5.5

Software package compatibility check

For all systems with (optionally) multiple boards and software versions, NTBV will release
packages that contain the supported software versions of each board. The following matrix may
be applicable (EXAMPLE!):
Examples

Main PCB

Communication board

Package 1

version A

version A

Package 2

version A

version B

Package 3

version B

version B

Each software file contains all compatible software versions of the partner boards. The system
will compare all available software files to know what the highest supported software package
is. It is then decided whether the selected software versions are a valid combination or not.

3.6

Optional features

3.6.1

Reading

With this option, computer printed documents can be handled fully automatically. Optical Mark
Recognition (OMR) and Barcode Reading (BCR) codes are possible.

A code is printed on each document, that contains information about the processing of the
sheets.

The code on the last sheet of the set always contains the insert instructions.

The other sheets carry the accumulate instruction.

If a parity check is used, this is checked on each sheet (only OMR).

The code must appear in the same location on every page regardless of the actual code
length.
Reading can be activated by a system specific license code. You can find further information on
reading in 4.3.5 Reading: OMR on page 4-8 and 4.3.6 Reading: BCR on page 4-11.
3.6.2

Flex reading

With this option, also non-Neopost (customer specific) codes and alternative document handling
algorithms can be recognised. Flex reading can be activated by a system specific license code
and by a customer specific setting that is saved in a physical dongle.
3.6.3

High capacity BRE maxiFeeder

The maxiFeederTM is a feeder that can be loaded with a high number of documents. This feeder
is intended to be used for Business Reply Envelopes (BRE), but also standard documents up
to 156 mm length can be processed with it. The maxiFeederTM is auto-detected by the system
when it is switched ON. This makes it easy to switch over from the standard document feeder
to the maxiFeederTM and vice versa.
To make use of a maxiFeederTM it is not necessary to (re-)program the jobs.

rev. 1.0 - 12/2009

3-19

075.1

3.6.4

Service Manual

Insertn Frank

With this option, in line franking by a connected franking machine can be realised. When a
functioning communication line with the franking machine is present, it is also possible to set
the franking machine and to select a franking job.
Insertn Frank can be activated by a system specific license code. In order to do this, the
communication board and the modem board need to be installed.
3.6.5

Online services

Online services enable the Sales Organisation to remotely manage and maintain a system that
is installed at the customer.
This option needs to be activated per system by the sales organisation. In order to do this, the
communication board and the modem board need to be installed.
3.6.6

High Capacity Vertical Stacker

The High Capacity Vertical Stacker is used to stack filled envelopes. The High Capacity Vertical
Stacker can store up to 325 filled envelopes. The High Capacity Vertical Stacker can be equipped
with Mail Piece Production Control (MPPC).
3.6.7

Side exit

The system can be equipped with a side exit and catch tray. The side exit can be fitted instead
of the standard envelope receiving tray. The side exit allows a conveyor or a franking system to
be fitted in line with the system.
The side exit can also be used with a receiving tray which is delivered with the side exit. The
receiving tray can be fitted to the left or to the right of the side exit to achieve vertical stacking.
3.6.8

Mail Piece Production Control (MPPC)

The folding and inserting system can be equipped with Mail Piece Production Control. This option
enables the system to verify the inserted documents or sets of documents with a database,
which is generated when you print the documents. The system gives a warning when a mail
piece is missing at the exit of the inserter.

3-20

rev. 1.0 - 12/2009

Service Manual
4

User interface

4.1

075.1

Operator menus

For an explanation of the Operator menus, see the Operator Manual.

4.2

Job and supervisor menus

For an explanation of the Job menu and Supervisor menu, see the Operator Manual.

4.3

Service menu

See the following flowchart for an overview of the various menus:


Menu
Supervisor Menu
4351

2546
Supervisor menu
(See operator manual)

Service Menu

Remove
blockage

System
settings

Service
tests

Diagnostics

Online
services

OMR

Start test

Server
settings

Power up

System
output

BCR

Error
counter

Reset CB
data

Folder
offset

Document
offset

Test CB

Flap closer
offset

BRE offset

Actuator
tests

Configuration

Secure jobs

Run in

Localisation

Flap closer

Sealing on
franking
machine

Digital
inputs

Last
error list

Service
counters

Photocells

DFC test

Reading

Job settings

Software
versions
Reset data

Envelope
only mode

Folder
ratio

rev. 1.0 - 12/2009

Touch
screen

Stop key

4-1

075.1

4.3.1

Service Manual

System settings

Power up
In this menu you select if you want to display the language menu after you switch on the system.
Folder offset
Two timed cams discs are used for the folding process. There is one cam disc for each folding
table. The timing is determined by the length of the sheets to be folded.
Given tolerances in the activation times of the clutches involved, this menu provides for an
equivalent shift in the folding positions to compensate a clutch activation time that deviates from
the average value.
In the folder offset menu:
1
2
3

Select the folder.


Set the offset in the folding position between -20 mm and +20 mm.
Process test material to see if corrections in these settings are required.

Flap closer offset


Use this menu to adjust the timing of the activation of the sealing solenoid (So3). You can use
this function to improve the sealing process. The timing has influence on the position of the filled
envelope with its flap fixed between rollers 21 and 22 prior, before it is transported between the
sealing rollers. This position can be adjusted between -10 and + 10 pulses (with respect to the
default envelope position). You can also adjust the flap closer offset per job (Service menu, Job
settings, flap closer). That setting overrules this system setting.
Configuration
Use this menu to view the configuration.
In this menu you can set the gap separation. In case the lowest feeder is not an automatic feeder
but a special feeder, change the gap separation on feeder 1 to Yes.
Localisation
Use this menu to set:

the language of the operational user interface


Currently the options are: English USA, English UK, Dutch, French, German, Spanish, Italian, Katakana, Swedish, Norwegian, Danish, Portuguese, Russian, Hungarian and Czech.

the service telephone number

the document standard size

machine type

date format
Software versions
The software version screen shows the software versions that are present in the total system.
Reset data
There may be situations in which it is necessary to restore the system settings to their states at
the beginning of the systems operational life. To this purpose the menu item Reset Data is
present.
Make sure all paper is removed from the machine, before you start Reset data. This is necessary
because the data resetting includes readjusting of the photocells.

Press Reset counters to reset all counters (daily counter, counter since last service visit and
counters for the envelope hopper and feeders).

4-2

rev. 1.0 - 12/2009

Service Manual

075.1

Press Reset data to start the reset process. This results in clearing all the data in the FRAM
memory of the system.
If you want to restore the default data in mm and ISO values, press Load defaults mm.
If you want to restore the default data in inches, press Load defaults inch.

Note 1: The changes made by this reset data operation are irreversible! All changes
made on the previous factory settings will be lost.
Note 2: The value of the counter Since installation, the Last error list and the Error
counter are not deleted when you restore the system.
Folder ratio
The folder ration determines the speed at which the document set enters the folding table. The
folder ratio is the ratio between pulses and mm. The ratio can be adjusted between 0.940 and
0.950. The optimum value is 0.945.
4.3.2

Job settings

System output
Use this menu to select operating mode Mode 1 or operating mode Mode 2, for each of the jobs
and loadn Go. Mode 2 is the default setting.

Mode 1 focuses on the versatility of paper parameters (paper thickness; document length),
i.e.: ensures for correct operation even under the most extreme paper conditions. Mode 1
should be used for a paper thickness of 65 g/m or less or a document length of 12 inch or
higher.

Mode 2 focuses on high speed. Mode 2 should be used for all other jobs.
See 3.4.3 Collating the document set on page 3-8 for an explanation of Mode 1 and Mode 2.
Document offset
The vertical transport of documents fed by the various feeders is arranged in such a way that
the documents are partially overlapping each other. This overlapping scheme ensures that the
documents are properly aligned in the collator area.
In the document offset menu you can set the extend to which the documents are not
overlapping each other, i.e. the document offset value. The default value is 50 mm (2.0 inch).
The document offset can be varied between 20 mm (0.8 inch) and 75 mm (3.0 inch).
BRE offset
If a document is longer than the set address fold but shorter than the envelope height, this
document sometimes will be unnecessarily folded. Under certain conditions this document can
be prevented from being folded. This can be implemented with the menu BRE offset (BRE
means Business Reply Envelope).
For each of the jobs 1 through 25 and Lng (loadn Go) an offset can be switched on or off using
the arrow button.
In the case of offset on the last document that had been added to the set prior to further
processing will be shifted from the rest of the set (offsetting), i.e. this document will be held
back during a certain distance. This means that the trailing edge of this upper document leaves
the collator last. This document will not be folded. During insertion into the envelope the
documents of the set will be realigned.
The conditions are:

The feeder that supplies this upper document (BRE) is set to one document per set (no multi
feeding).

rev. 1.0 - 12/2009

4-3

075.1

Service Manual

The document directly beneath this document must be at least 60 mm (2.4 inch) longer
than the BRE.
The upper document must be longer than the set address fold.
The folding mode is either single fold or letter fold (no Z-fold).
The upper document must be shorter than the envelope height.

Note: It is possible to use the BRE offset for a BRE and an enclosure (card) in one set.
The extra condition is that this enclosure is equal to or smaller than the set address fold
and should be placed direct underneath the BRE in the set.
The whole BRE offset is based on friction between documents within a set. Therefore it is
necessary to make use of these conditions to reduce the risk of bad transporting, folding and
inserting.
In some cases the BRE option is automatically switched off if one or more of the abovementioned conditions are not met. Therefore it is safe to switch the BRE option on, unless this
option will never be used.
Secure jobs
With the Secure job menu the selected job can be secured, i.e. locked. This job can not be
deleted and can not be changed in the job menu either. However, a locked job still can be copied
into another job that can be modified.
Flap closer
The flap closer offset is set in the System Settings menu, Flap closer offset. In the Flap closer
menu in the Job Settings menu you can adjust the timing of the activation of the sealing solenoid
(So3) on a per-job basis. You can use this function to improve the sealing process per job. The
timing has influence on the position of the filled envelope with its flap fixed between rollers 21
and 22 prior, before it is transported between the sealing rollers. This position can be adjusted
between -10 and + 10 mm (with respect to the default envelope position).
4.3.3

Service tests

Photocells
This machine uses so-called intelligent photocells. The currents of the photocell transmitters are
adjusted in such a way that the no-paper output voltage of the photocell receiver is within a
certain voltage range of the photocell receiver. In this way, a reasonable amount of dust on the
photocell sensors can be compensated for. The control mechanism ensures that very reliable
paper and no paper decisions are being made, based on the paper photocell condition.

The screens provide real-time information on the various paper photocells. You also can see if
the relevant photocell sees paper.

4-4

rev. 1.0 - 12/2009

Service Manual

075.1

Press the Cal. button to adjust the photocells.

Note: Before readjusting the photocells it is strongly recommended to remove all paper
from the machines and to clean all the sensors (both transmitter and receiver!) of the
photocells.
After the photocell have been adjusted, the percentages in the screens should be lower (if the
cleaning advice was followed). If no paper is present, the photocell output voltage should have
a value between 0.8 V and 1.5 V. A value below this voltage range indicates that the photocell
is too dirty. A value above this voltage range may occur if after readjusting a photocell dust is
removed. In both cases, the photocells must be adjusted.
If the photocell current percentage is below 75%, the message OK is shown. A percentage
between 75% and 99% results in a Clean message. The photocell should be cleaned before
resetting the photocells. The message Defect is shown when the percentage is 99% or 100%
Digital inputs
The digital input screens show:

The status of the three safety switches: MS1 (collator switch), MS2 (front switch) and MS3
(loc switch)
The status is real time: a change is reflected in the displayed status. This allows you to
easily check the correct operation of the three microswitches.

The status of the collator stop sensors: if the sensor is covered (closed) or not (open).

If the water reservoir is present and if the water level is sufficient

The status of the two folder cam disks (SPH3 & PD3; SPH4 and PD4)
You can also test the folder cam discs. During the test the relevant cam disc moves one
half cycle. The cam disc status changes from open to covered or from covered to
open. If you press two times on a test key the cam disc has made a full cycle.

The pulse disc and SPH2 for the main motor M2 (pulse disc central)
You can also test the pulse discs of the motors. Both the speed and the quality (duty cycle)
are tested. Detailed information is obtained via the minimum (Min.) and maximum (Max.)
value. The speed range should be between 75% and 125%. The Distance (Duty cycle)
value should be between 50% and 150%. If this is the case the message 'Good' is displayed.
The speed is checked by measuring the average pulse width and comparing it to the initial
value. When the speed is much lower than the initial value, check the mechanical load. If it
is higher, the pulse disc might be loose.
The Distance (duty cycle) is measured of each pulse and the minimum and maximum values are shown. When a pulse (an indented area) is not detected (for example because of
dust build up) the pulse distance will show a value of Min. 0% and/or Max. 200%.

The pulse discs SPH1 for the collator motor M1 (pulse disc collator)
Actuators tests
From this menu you can select an actuator and activate it. Some tests are only possible with
running motor. With the upper button you can switch the motor off or let it run continuously
during actuator tests.
The following tests are possible:

Main motor (M2): the motor runs as long as the Test button is pressed.

Fingers magnet (So1): the fingers move forward as soon as the Test button is pressed. Only
after releasing the Test button the fingers will move back to their rest position.

Eject roller magnet (So2): press the Test button and keep it pressed: the solenoid is
activated and deactivated after a short time.

Closer magnet (So3): press the Test button and keep it pressed: the solenoid is activated
and deactivated after a short time.

rev. 1.0 - 12/2009

4-5

075.1

Service Manual

Envelope track clutch (CL8): press the Motor ON button and press the Test button. The
envelope track clutch is activated.
Stacker clutch: press the Motor ON button and press the Test button. The stacker clutch is
activated.
Brush magnet (So4): press the Test button and keep it pressed: the solenoid is activated
and deactivated after a short time.
Shunt forward: the collator motor M1 runs and clutch CL4 is activated
Shunt reverse: the collator motor M1 runs and clutch CL5 is activated
Collator run in: the collator motor M1 runs in the direction of the document stop position
Collator run out: the collator motor M1 runs in the direction of the folder
Folder: the collator motor M1 runs and clutch CL4 is activated
Folding table 1: the folding table turns a half fold cycle. If you press the Test button for the
second time the folding table returns to its original position.
Folding table 2: the folding table turns a half fold cycle. If you press the Test button for the
second time the folding table returns to its original position.
Collatorstop to A: both collator stops move up and down
Collatorstop to B: the centre collator stop moves up and down
Collatorstop to C: no collator stop movement
Feeder clutches: the main motor M2 is switched on and the relevant feeder clutch is
activated if the button is pressed.
The maxiFeederTM option is only available if the maxiFeederTM is present. As long as the
button is pressed, its motor will run.

Run in
This screen has a counter (with default value of 500) that shows the number of process cycles
that will be executed, without paper or envelopes present in the machine.

Note: Never execute the run in test with any documents present in the machine. The
timing of the actions for a simulated process cycle are fixed, they are not based on
parameters such as the document length. A run in test with documents present in the
machine would only result in severe paper jamming.
After pressing the Start/Stop key, the run in test will start/stop. The machine stops
automatically if the counter value is zero.
If some covers are removed (but not the safety covers!), you can watch the sequence of the
various mechanical actions, which reflect the sequence of events during normal operation.

4-6

rev. 1.0 - 12/2009

Service Manual

075.1

DFC test
The DFC screen shows the real-time DFC output voltage, expressed in millivolt. For testing the
DFC it is best to start the system with paper underneath the DFC sensor (and covering the feeder
photocell too). This results in starting the adjustment procedure. The voltage should be approx.
4.1 V when a single sheet (80 grams/20 lb) is below the sensor (the voltage of a non-adjusted
DFC, without paper, is approx. 5 V). When this sheet is removed the voltage will drop with
approx. 0.25 V. The voltage drop depends on the thickness/quality of the paper. The table gives
an indication how much the voltage will drop with the relevant paper qualities.
Paper quality
(g/m2)

Voltage drop
(V)

65

0.2

80

0.25

120

0.35

160

0.5

Although the readings are correct it still could be that the DFC is not functioning correctly in
AUTO mode. It is recommended to clean the moving parts of the DFC to make sure that dust or
paper particles are not affecting the DFC functioning.
If you restart the system, the DFC voltage is erased from memory, has no reference and shows
some unexpected value. After a first sheet is passed through the feeder the DFC will be
calibrated at about 3.96 voltage. For the next sheet the DFC is functioning correctly.
During normal operation the system automatically recalibrates. Manual DFC testing and
calibration can be easily done by removing the cover (with an opened loc) and manually turning
the feeder separation gear. In the service menu DFC test menu, the voltage can be verified.
Touch screen
In the Touch screen tests menu you can verify the correct functioning of the touch screen. If you
press Test touch screen, a graphical object will be displayed on the screen at each point where
the screen is touched. The screen can be touched with either a finger or a (non-scratching) pen.
If the area touched does not correspond with the displayed object, the touch screen should be
calibrated. To do this, use the Calibrate touchscr. button and follow the commands on the
screen.
Envelope only mode
If you set the envelop only mode to On, all jobs will only process envelopes. Use this mode for
a service test without documents.
Stop key
For testing purposes it is possible to create a stop key in the user interface (Mode is On). This
stop key appears as soon as the system runs a job. Deactivate this key (Mode is Off) when you
have finished servicing the system.
If you press this extra stop key the system does not stop immediately, but on the first
opportunity while processing. Because of this there can be incomplete sets in some parts of the
system.
4.3.4

Service counters

This menu allows you to read, set, or reset the service counters:

The Since last visit counter can be reset.

rev. 1.0 - 12/2009

4-7

075.1

Service Manual

The Since installation counter is displayed.


The next visit after counter can be incremented in 5000 steps to a maximum value of
6.000.000 steps. A value under 5000 results in the value OFF.
The feeder counters (1 through 3) can be reset to zero.
The envelope hopper counter can be reset to zero.

4.3.5

Reading: OMR

OMR code definition


The OMR code definition menu allows you to define the OMR reading codes. The number of
different menu items depends on the level of OMR, see the table.
Per item choose between Yes and No (toggling function). The line spacing can be changed in
steps of approximately 0,03 millimetre. The Lpi value reflects the number of lines per inch, the
millimetre value is the distance between two successive marks.
The Table summarizes the possibilities of the OMR code.
Note the following:

When some functions are not used, marks will shift up.

The minimum marks in Level 1 are: Start mark + accumulate or insert. That is 2 marks in
total. However, it is highly recommended to add a third mark, the safety mark in the
minimum configuration.

The feeders programmed as selective feeder cannot be used as a reading feeder.

Of the marks 'Insert', 'Divert' or 'Stop' only one should be printed on each single document
to indicate the end of the set. The marks are so called 'mutually exclusive'.

The divert and continue mark cannot be used. The divert and stop mark will make the set
stop in the collating area.

If a level increase occurs, the extra functions will use the default setting (= off). When the
level is decreased the not available functions will be switched off without giving any error
message.

The sequence will be reset after power up; a job change; a successful clear action or an
error message.

When parity is used the parity of the printed marks should be even.
Reading code parameter

Value

Description

Level

Start mark

Yes

Start mark

Basic, Advanced

No

No start mark

Basic, Advanced

Mark

Mark is insert; space is accumulate

Basic, Advanced

Space

Mark is accumulate; space is insert

Basic, Advanced

Yes

Divert mark (implemented as a stop


mark)

Advanced

No

No divert mark

Advanced

Yes

Stop mark

Advanced

No

No stop mark

Advanced

Yes

Selective feed on station 1

Advanced

No

No selective feed on station 1

Advanced

Insert on

Divert mark

Stop mark

Selective feed 1

4-8

rev. 1.0 - 12/2009

Service Manual

075.1

Reading code parameter

Value

Description

Level

Selective feed 2

Yes

Selective feed on station 2

Advanced

No

No selective feed on station 2

Advanced

Yes

Selective feed on station 3

Advanced

No

No selective feed on station 3

Advanced

Yes

Mark is no sealing, space is sealing

Advanced

No

No sealing control

Advanced

No

No sequence check

Advanced

1 (mark)

Sequence check 1 with 1 mark

Advanced

2 (marks)

Sequence check 2 with 2 marks

Advanced

3 (marks)

Sequence check 4 with 3 marks

Advanced

Yes

Parity check, based on a parity mark

Basic, Advanced

No

No parity check

Basic, Advanced

Yes

Safety mark

Basic, Advanced

No

No safety mark

Basic, Advanced

4 10 lpi

Line spacing in increments/


decrements of 1/32" (keys 4 and 5);
Displayed in 2 digits in lpi and mm

Selective feed 3

Sealing control

Sequence check

Parity check

Safety mark

Line spacing

In the OMR code type menu you can choose Legacy. These definitions are meant for the former
PFE code definition as used on the Minimailer 2, 4 and Easy start.
Within the code definition Legacy the following functions are available and can be defined:
Reading code parameter

Description

Level

Gate mark

Not selectable, always on

Basic, Advanced

Insert on

Not selectable, always on (insert on


mark)

Basic, Advanced

Yes

Parity check, based on a parity mark


(even parity)

Advanced

No

No parity check

Advanced

Yes

Mark is no sealing, space is sealing

Advanced

No

No sealing control

Advanced

Yes

Selective feed on station 2

Advanced

No

No selective feed on station 2

Advanced

Yes

Selective feed on station 3

Advanced

No

No selective feed on station 3

Advanced

Parity

Unseal

Selective feed 2

Selective feed 3

rev. 1.0 - 12/2009

Value

4-9

075.1

Service Manual

Reading code parameter

Value

Description

Level

Selective feed insert

Yes

Selective feed on station 1

Advanced

No

No selective feed on station 1

Advanced

Yes

Stop mark

Advanced

No

No stop mark

Advanced

Off

No sequence check

Advanced

1 (mark)

Sequence check 1 with 1 mark

Advanced

2 (marks)

Sequence check 2 with 2 marks

Advanced

3 (marks)

Sequence check 4 with 3 marks

Advanced

4 (marks)

Sequence check 8 with 4 marks

Advanced

5 (marks)

Sequence check 16 with 5 marks

Advanced

Line spacing

4 10 lpi

Line spacing in increments/


decrements of 1/32" (keys 4 and 5);
Displayed in 2 digits in lpi and mm

Read direction

Yes

Reading direction is reversed

Advanced

No

Normal reading direction

Advanced

Halt

Sequence check

OMR code test


Use this menu to test the OMR reading head (RH1) and, if necessary, to readjust the relevant
OMR electronics.
1

Select Adjust to start testing the reading head.


The settings of the current job are used for this test. This implies that an OMR job must be
selected, otherwise the text Select a job with OMR will appear. If the OMR codes on the
paper used differ from the OMR codes for the current job, the number of marks that have
been read are incorrect.
After selecting Adjust, another menu appears. Information about the number of OMR test
sheets to be placed in the upper feeder is first shown.
Select Start adjust to start the OMR adjustment.
The text Adjusting appears. The end result will either be:
- Adjusting OK
- Adjusting FAILED
If readjustment of the OMR electronics was successful, Save and exit is displayed.
Select Save and exit to return to the original OMR menu. This menu now shows the benefit
of readjusting the OMR electronics.

Select the Test key to show:

Mark quality (the quality of the marks: bad, good or very good)
The mark quality is either:
Bad: Mark amplitude < 0.6 V
Good: Mark amplitude between 0.6 V and 1.5 V
Very good: Mark amplitude higher than 1.5 V

Marks (the number of marks that have been read)

Gain (the gain of the amplifiers involved in the OMR electronics, the values are 1, 3, 5 or 7)

Vp-p: peak to peak voltage


Select the OMR info key to display the information screen. This screen shows additional OMRrelated information. This information is based on the last read document and the job settings
(OMR code type etc.). The displayed information is what is interpreted from the read OMR code.

4-10

rev. 1.0 - 12/2009

Service Manual

075.1

Select Show OMR to display a graphical representation of the marks that had been read
(oscilloscope function). The information shown is derived from the most recently read document.
The information screen shows the time-dependant OMR output voltage and the reading window.
See following figure.

The start of the window is represented by a vertical line, the end of the reading window is also
represented by a vertical line. In between the marks should be given where the position of the
marks related to the window position is also giving some information, i.e. when the first mark is
very close to the opening of the window; this could mean that the window position is
programmed wrong.
The upper horizontal dotted line represents the noise level, i.e. the white level. The lower
horizontal dotted line represents the level below which a mark (i.e. detection level) has been
detected. The detection level is determined when the adjustment procedure is performed. The
detection level is 60% of the top level. A mark is detected as an OMR-mark when more than 5
digital samples consecutively are below the detection level.
The numbers 1 through 6 indicate where a mark is expected. The distance between the numbers
is exactly the same as the programmed line spacing. Select the arrows to scroll to the left or the
right. Scrolling to the right shows a later point in time; scrolling to the left shows an earlier
situation.
4.3.6

Reading: BCR

Read config sheet


The button Read config sheet allows you to read Barcode Reading (BCR) settings from a BCR
configuration sheet. Follow the instructions on the screen.
BCR code definition
The BCR Code definition allows you to define the reading codes for barcode reading.
Per item choose between Enabled, Disabled or Ignored.
The table in this section summarize the BCR code options.
Note the following:

You can only select feeder 2 as a reading feeder if Selective feed 2 is set to Ignore.

If a level increase occurs, the extra functions will use the default setting (= off). When the
level is decreased the not available functions will be switched off without giving any error
message.

The sequence will be reset after power up; a job change; a successful clear action or an
error message.

If a functionality is not available on the machine, but printed in barcodes, set this
functionality to Ignore. This offers the possibility to use the same coding throughout
different machine types.

rev. 1.0 - 12/2009

4-11

075.1

Service Manual

The position of a reading functionality depends on the availability of other functions and on the
number of characters you choose for a function. If a functionality is disabled, the other functions
shift upwards.

Note: The code always should start and end with an * (asterisk symbol).
Neopost barcode scheme
Reading code
parameter

Code
length

Default
Description
settinga

Page N of M

M: 0 - 2
N: 0 - 2

D, 0
D, 0

n<m: accumulate
basic
n=m: insert
n>m: invalid, sequence error, divert
The field Chars shows the number of character
positions available for N / M:
1, 2: 1 or 2 character positions
1 S, 2 S: 1 or 2 character positions with N and
M in reverse order (M first, then N)

Sheet Sequence

0-3

E, 3

Sheet counter
If a sheet number is missing, an error is
generated.

advanced

Group Sequence

0-3

D, 0

Set counter
If a set number is missing, an error is
generated

advanced

Insert / Accumulate

1 bitb

Insert and accumulate command

basic

Divert 1

1 bit

Divert and continue


advanced
Divert and stop
(see Divert on page 4-13)
(On 075.1 both will be interpreted as divert to
collator and stop)

Divert 2

1 bit

Not possible on 075.1, 080.1 and 086.1. If


these functions are available in the barcode
set them to Ignore.

advanced

Selective Feeds

1 bit each E

A maximum of 7 feeders (086.1: feeder 7 is


versaFeeder) is available for selective feed

advanced

Do not glue

1 bit

Sealing control: enable or disable sealing


(086.1 only)

advanced

Envelope selection 1 - 3 1 bit each E

Not possible on 075.1, 080.1 and 086.1

advanced

Exit. Sel. 1

Stacker or side exit (086.1 only)

advanced

4-12

1 bit

Level

rev. 1.0 - 12/2009

Service Manual

075.1

Neopost barcode scheme (Continued)


Reading code
parameter

Code
length

Default
Description
settinga

Level

Exit. Sel. 2

1 bit

Present on deck & continue


Present on deck and stop (086.1 only)

advanced

Exit. Sel. 3

1 bit

Not possible on 075.1, 080.1 and 086.1

advanced

Stop

1 bit

Stops the inserter

advanced

Customer ID

0 - 16

D, 0

If customer ID equals the ID on the previous


page: accumulate
If customer ID is different from ID on the
previous page: insert the set

basic

(not possible on 075.1, needs reverse reading)


a.
b.

E is Enabled, D is Disabled
4 bit values represent one barcode character

Divert
In the BCR Code definition menu you will find the following settings that are not mentioned in
the table:

Divert and continue

Divert and Stop

Present on deck and continue

Present on deck and stop


These settings are covered as follows:

Divert & Continue and Divert & Stop are directly linked to the Divert 1 function and the separate
Stop function. This means:

When you enable Divert & Continue, Divert 1 is also enabled automatically.

When you enable Divert & Stop, both Divert 1 and the Stop function are enabled
automatically.
In both cases do not change the settings of the Divert 1 and the Stop function, because this will
change the setting of the Divert & Continue and Divert & Stop function.

Note: The reason for this behavior is to have different DS systems support the coding
scheme.

rev. 1.0 - 12/2009

4-13

075.1

Service Manual

BCR code test


Use this menu to test the reading head (RH1) and, if necessary, to readjust the relevant reading
electronics.
1

Press Adjust to start testing the reading head.


The settings of the current job are used for this test. This implies that a BCR job must be
selected, otherwise the text Select a job with BCR will appear.
After pressing Adjust, another menu appears. Information about the number of BCR test
sheets to be placed in the upper feeder is first shown.
Press Start adjust to start the BCR adjustment.
The text Adjusting appears. The end result will be either:
- Adjusting OK or
- Adjusting FAILED
If readjustment of the BCR electronics was successful, Save and exit is displayed.
Press Save and exit to return to the original BCR Test menu.

When testing the reading head the displayed test information is:

Barcode quality (the quality of the marks: bad, good or very good)
The quality is either:
- Bad: Mark amplitude < 0.6 V
- Good: Mark amplitude between 0.6 V and 1.5 V
- Very good: Mark amplitude higher than 1.5 V

Vp-p: peak to peak voltage


Press Show BCR to display a graphical representation of the barcode that has been read
(oscilloscope function). The information shown is derived from the most recently read document.
4.3.7

Diagnostics

Start test
This test checks if all motors, clutches and sensors are correctly connected. The system test
derives the status of the actuators and clutches by briefly activating the actuators and then
measuring the current.
Error counters
In the Error counters menu a list is given of the top 40 occurred errors. The errors are sorted
based on quantity. That means that the errors occurring most frequent are in the top of the list.
Press clear to clear all error messages.
Last error list
This menu displays the last 50 errors that occurred. Besides the error code also the job number
and the corresponding counter value are given.
Press clear to clear all error messages.
4.3.8

Online service

Server settings
Use this menu to enter:

the IP address of the server

the server port of the server


Reset CB data
Use this menu to clear the data on the communication board, and to reset the status of the
communication board to undeclared.

4-14

rev. 1.0 - 12/2009

Service Manual

075.1

Once the communication board has been reset, it can be used in another system. As soon as the
communication board is installed in another system (i.e. during a board replacement), it will be
automatically reset.
Test CB
Select Test CB to check the following:

the serial port


The system checks if the RS-232 serial port and cable are working correctly. Connect the
special test plug, and then select Test CB. The special RS-232 test plug has pins 2 and 3
jumpered together. During the test a send, response is sent through the cable and plug
(Rx, Tx).

the modem
The system checks if a modem is present and if there is a dial tone.

the real time clock


The system checks if:
the communications board has a battery, and the battery is working correctly.
the communications board clock is working correctly.
Fail or Pass will be displayed for each item depending on the result of the test.
4.3.9

Remove blockage

During system start-up, the serial number stored on the main board is compared to the original
serial number in the ID-tag. After a main board or ID-tag has been replaced, the machine may
have lost it's identity, backup counter, and enabled features. This will block the normal operation
of the machine.
The machine will show error INS-SYS-102 (serial number mismatch) during machine start-up.
The user can still access all menus, but the machine will be blocked from running jobs or loadn
Go.The blockage can only be removed if a service technician accesses the password protected
service menu and confirms that the ID-tag or main board has been replaced.
To do this: from the Main menu select Job menu (and enter the PIN code), and then select
Remove blockage.
Main board replacement
After a main board replacement, No will be answered. The identity, backup counter and enabled
features will be restored from the ID-tag.
ID tag replacement
After an ID-tag replacement (factory prepared), Yes will be answered. As a second question, you
will be asked to enter the new total counter of this inserter. A backup of this counter will be
copied to the new ID-tag.
4.3.10 Sealing on franking machine
This option is only available if insertn Frank is set to level 2 or 3. By default, sealing is disabled
on the franking machine when an insertn Frank job is selected. This service menu option,
allows you to ignore the sealing settings of the franking machine.

rev. 1.0 - 12/2009

4-15

075.1

4-16

Service Manual

rev. 1.0 - 12/2009

Service Manual
5

The 075.1

5.1

Transport, storage and installation

5.1.1

075.1

Transport

The system, including all accessories, is transported in one box. The box is attached onto a
pallet. Handle the package with care.
Warning

Do not turn the box on its side.

Prevent the box from falling over.

Prevent the box from shaking.


Note
When shaking (during transport) is expected, follow this procedure:
1. Remove the feed hoppers.
2. Tighten the feeders.
3. Secure the collator.
5.1.2

Unpacking, installation and storage

Before you start


1.

Verify that the system is suitable for the local mains voltage. Refer to the type plate.

2.

The power connection must be easily accessible. Place the system near a socket outlet with protective earth
connection.

Warning
The earth connection is essential for safety.

Unpacking instructions
1.

Remove the two blocks packaging material on top of the system.

2.

Verify that the following parts are available in the box:


-

inserter system (A)

a box with document feeders (E)

a box with one catch tray and one slide (B)1

a power lead (C)

a bag with three spare moistening brushes and a spare moistening cloth
(D)

optional accessories (maxiFeeder, side exit)

B
D

1. If the high capacity vertical stacker is part of the delivery, the catch tray and slide are not contained in the box.

rev. 1.0 - 12/2009

5-1

075.1

Service Manual

3.

Remove the box from the tray.

4.

Remove the blocks on both sides.

5.

Lift the system and place it for example on the optional furniture.

6.

Remove the packaging materials from the following places:


-

Cardboard below the loc, at the document insert position (A)

The foam blocks at the feeders (C)

Fixing pin from the top of the feeder tower (B)

Band and foam block at collator (D)

Note
Do not connect to mains yet.

In case of a high capacity feeder:


-

Cut both wire straps at the high capacity feeder (E).

Remove the transportation plate (F).

C
D

5-2

rev. 1.0 - 12/2009

Service Manual

075.1

Install feeders
Note
If a special feeder is available always install it on the lowest position.

1.

Hold the tray slightly inclined as shown in the figure.

2.

Place the front end of the tray underneath the two black rollers.

3.

Lift the tray (lifting the black rollers) until it is possible to hook the tray into
place.

Install slide and envelope catch tray


Note
The slide and catch tray are not delivered if the high capacity vertical stacker is
delivered.

1.

Attach the slide.

2.

Position the envelope catch tray into the holes underneath the envelope
hopper as shown in the figure.

3.

The distance A should be approximately 1.5 x the envelope height.

A
Install maxiFeeder (option)
1.

Install the maxiFeeder in the same way as the normal feeders.

2.

Connect the connector A to the socket B.

rev. 1.0 - 12/2009

5-3

075.1

Service Manual

Install high capacity feeder tray (option)


1.

Pull down lever A.

2.

Hook in the feeder tray.

3.

Release lever A.

A B C D E

Install high capacity vertical stacker (option)


1.

Hook in the vertical stacker.

2.

Connect the connector.

A B
Install side exit and catch tray (option)
1.

Remove the envelope catch tray and the slide.

2.

Hook in the side exit.

3.

Mount the new catch tray.

Fill the reservoir


1.
2.

Fill the reservoir B up to lip C with sealing liquid.

3.

Open the front cover A.


Close the front cover A.

5-4

rev. 1.0 - 12/2009

Service Manual

075.1

Connect the system to the mains power supply


Set language
1.

Switch on the system.

2.

Select the language for the display.

3.

Press No if the software asks if you want to select the language every time the system is switched on.

Online Services (option)


1.

Go to Supervisor menu, Online services, Configuration and enter:


-

Prefix if applicable

Date (in second configuration window)

Time (in second configuration window)

2.

Press the OK button.

3.

Press Connection, Connect for the initial declaration call.

4.

Press the i button to follow the status of the connection.

5.

The initial declaration call is finished if the System status shows "Pending declaration".

6.

Press Connect again for declaration.

7.

Press the i button to follow the status of the connection.

8.

The declaration call is finished if the System status shows "Declared".

Test the system


1.

Load document feeder trays.

2.

Load the envelope hopper.

3.

From the Home menu press New Job, Automatic.

4.

Press the 1x button. If necessary adjust address position, insert position and
insert fingers.

5.

Select a job and write down its fold settings.

6.

Press the 1x button.

7.

Verify that the folds are in the correct position. If not correct, adjust it
(service menu, system settings, Folder offset).

8.

Verify the flap closer quality. If not correct, adjust it (service menu, System settings, Flap closer offset).

Define jobs
Define any jobs according to the customers wishes / applications.

Storage
The system needs to be stored under the following conditions:

Storage temperature:

10 to 40 C (50 to 104 F)

Humidity:

30 to 80%

rev. 1.0 - 12/2009

5-5

075.1

Service Manual

5.2

Mechanical description

5.2.1

General
Warning
Disconnect the mains supply before performing any maintenance.
Warning
The covers and microswitches are fitted for your protection. Do not operate the
machine with any cover removed and with a microswitch cheated, or a hazard to
health will exist.

Throughout this manual the terms left and right-hand side and front and rear side of the machine
are used. These are made with the machine viewed from the input (document feed) side of the
machine.

5-6

rev. 1.0 - 12/2009

Service Manual

5.2.2

075.1

(Dis)assembly - Covers and plates

Right-hand side cover

RH

LH
To disassemble the right-hand side cover:
1
2
3

Open the upper unit by lifting the hand grip (2).


Remove (loosen) the five screws of the right-hand side cover (1).
To remove the cover, turn and move as shown in the figure.

rev. 1.0 - 12/2009

5-7

075.1

Service Manual

Left-hand side cover

RH

LH

To open the left-hand side:


1
2
3

Open the upper unit (1) and the hinged cover (4).
Remove (loosen) the two screws of the left-hand side cover (2).
Remove the two screws and loosen one screw of the inner cover (3).

5-8

rev. 1.0 - 12/2009

Service Manual

075.1

Top cover feeders, covers collator area, power supply cover

RH

LH
1
2
3
4

Remove the top cover feeders (1), the covers of the collator area (2), and the power supply
cover (3).
Remove the water tray.
Place the machine carefully at the right hand side on a felt path.
Slacken the three screws of the bottom plate (4) and remove the bottom plate.

rev. 1.0 - 12/2009

5-9

075.1

Service Manual

Covers upper unit

2
3

RH
4

LH
To easily access the interior, open the covers in the following order:
1
2
3

Vertical transport cover (4)


Top covers (1, 2, and 3)
Loc cover (5)

5-10

rev. 1.0 - 12/2009

Service Manual

5.2.3

075.1

(Dis)assembly - Electrical components

Note
When a board is installed and the system is switched on, you must check if the correct software
is installed. If the correct software is installed, the machine will start to synchronize with the
ID-tag (2994504Z). See Section 3.5.4 The ID-tag. If the board is new to the system, the
error message INS-SYS-501 will be displayed, which indicates that the serial number in the IDtag (2994504Z) does not match the serial number in the FRAM of the main board. This will
prevent the machine from working. Before you can use the system, you will have to remove
the blockage. See Section 4.3.9 Remove blockage.

Warning
Potential hazard may exist to electronic hardware in conditions with static
electricity. It is advised that, when handling electronic parts, an earth connected
wrist band is used in order to be permanently discharged from static electricity.
Main board

LH

To disassemble the main board:


1
2
3
4

Disconnect the wiring to the main board (1).


Remove the screw (2).
Lock washer and spacer.
Carefully pull the main board from the board holders as shown.

rev. 1.0 - 12/2009

5-11

075.1

Service Manual

ID-Tag
Ordering and installing new ID-tag:

When the ID tag fails, the system can continue running without using OMR or insertn
Frank features. At start up, and at each 100 cycles, the operator will see an error message
ID/Option memory update fails or ID memory not detected.

Place an order for a new ID-tag for a specific serial number.

NTBV will send you a replacement ID-tag containing the same features as known by NTBV
for that serial number.

As the old ID-tag may contain valuable features, double check the provided features with
your own administration.

When correct, make sure you destroy the old ID-tag (ID-tags may never be used on other
systems!).

At the installation of the new ID-tag, the system will go into blockage. In the service menu
you can de-block the system and set the counter.
Display board

1
4

LH

Before removing the display (2) or the display board (3), the complete display bracket must be
removed from the system.
1
2
3
4
5
6

Remove the top cover (1).


Remove the two screws that hold the bracket to the system.
Disconnect the main cable display (4).
Withdraw the display bracket carefully.
Disconnect the wiring (5 and 6) so that the display board can be removed.
Carefully remove the display board.

5-12

rev. 1.0 - 12/2009

Service Manual

075.1

LH

To remove the display:


1
2

Remove the four screws (3) which secure the display (2) to the mounting bracket display
(6).
Withdraw the display (2) carefully.

Note
Connect the wiring before replacing the display. Be sure to replace the four spacers (5).

rev. 1.0 - 12/2009

5-13

075.1

5.2.4

Service Manual

(Dis)assembly - Feeder modules and vertical transport right-hand

The feeders, the vertical transport and the fold unit are driven by belt (4) and the accompanying
pulleys, gears, etcetera as shown in the following figure.
When the machine is running the four transportation axles are continuously driven by the belts
(4, 5 and 6). The three upper transportation axles are equipped with a clutch and a pulley.
When, for example, the clutch (2) is activated, the accompanying feeder is driven by pulley (3)
and belt (1) and a document is fed to the vertical transport track.

1
2

5
3
4

RH

5-14

rev. 1.0 - 12/2009

Service Manual

075.1

Drive mechanism right-hand - Belts and pulleys

2
3
4

RH
Belt 4
1
2
3

Slacken the two screws of the belt tensioner (5).


Shift the belt tensioner downwards.
Remove belt 4 from the pulleys.

Pulley 1
1
2
3

Loosen the main belt, PJ belt and drive belt inserter.


Remove the spring clip.
Slide the main pulley of the axle.

Pulleys 2 and 3
Pulleys 2 and 3 are snapped to their cyl. pins. They can be removed by pulling them of the axle.

rev. 1.0 - 12/2009

5-15

075.1

Service Manual

12 13 14

RH
Belt 4
1
2

Slacken the hexagonal head screw of the belt tensioner (1).


Remove belt 4 from the pulleys.

Belt 7
Belt 7 is removed in the same way as belt 4.
Pulleys 3, 5 and 6
Pulleys 3, 5 and 6 are snapped to their cyl. pins. They can be removed by pulling them of the
axle.
Pulley 8
1
2
3
4
5

Remove the hexagonal head screw of the belt tensioner (2).


Withdraw the tensioner.
Slide the pulley 5 from the axle.
Remove the cyl. pins from the axle.
Slide pulley 8 of the axle.

5-16

rev. 1.0 - 12/2009

Service Manual

075.1

Drive mechanism left-hand

6 5 4 3

LH

Belt
1
2

Unhook the tension spring (2) from the inside frame.


Remove belt 1 from pulley 3.

Clutch and Pulley


1
2
3

Disconnect the wiring of the clutch.


Remove the spring clip (6).
Slide the clutch (5), the disc (4), and the pulley (3) of the axle.

rev. 1.0 - 12/2009

5-17

075.1

Service Manual

Drive mechanism left-hand high capacity feeder

Belts
1
2
3
4

Remove
Remove
Remove
Remove

nut (1) and the spring clips that hold plates (2) and (3).
the plates.
belts 4, 5, and 6.
the pulleys if necessary.

Clutch and Pulley (7)


1
2

Disconnect the wiring of the clutch.


Remove the spring clip and slide the clutch (8) and pulley (7) from the axle.

5-18

rev. 1.0 - 12/2009

Service Manual

5.2.5

075.1

(Dis)assembly - Feeders

All the feeders are provided with dividable drive axles. Removal of the complete feeders:
1
2
3

Remove the hoppers.


Remove the extension part of the drive axle (7, refer to the following figure). Take care that
it is a left side screw-threaded axle end. Each feeder can now be removed separately.
Fix the main axle by a pin on one of the holes.

At the right-hand side the feeders are equipped with a tension spring for proper lifting of the
feeder. The tension spring is hooked on a mounting bracket at the frame.
Note
Do not remove the mounting bracket or exchange the tension spring from one to another
feeder. Each spring is specially adjusted from the factory by positioning the mounting bracket.
If you remove the spring, first mark the hole it is attached to.
Top feeder (feeder 3)

7
8

LH

1 2 3 4 5 6

9 10 11

RH

To loosen the top feeder:


1
2
3
4
5
6
7
8
9
10

Unhook the tension spring (10, see note above) from the screw (9) (on the right-hand side
of the feeder).
Disconnect the wiring of the feeder.
Cut the wire straps.
Remove the wiring from the left-hand inside frame.
Remove the spring clip (6), clutch (5), belt (3), and pulley (4) from the top transportation
axle.
Unhook the tension spring (8) from the inside frame.
Remove axle part (7) of the lower transportation axle.
Remove the top transportation axle (11) by moving it in the right-hand direction.
Remove the screw of the left-hand and right-hand hinge pin (2) of the top feeder.
Remove axle 1 out of the lock.

rev. 1.0 - 12/2009

5-19

075.1

Service Manual

RH

LH

A
To remove the feeder:
1
2
3

Move the feeder a bit downstream as indicated (A).


Lift the right-hand side of the feeder first.
Remove the feeder from the machine (B).

Note
Be careful when replacing feeder 3, the hinge pin at the right-hand side is locking the ball
bearing.

5-20

rev. 1.0 - 12/2009

Service Manual

075.1

High Capacity Feeder

RH

LH
1 2 3

4 5

To loosen the High Capacity Feeder:


Note
Before you unhook tension spring (1), mark the small hook it is attached to (see A in the
figure).
1
2

Unhook the tension spring (1, on the RH side of the feeder).


Unhook the large tension spring on the LH side of the feeder.

Note
Keep the springs separated. They are not interchangeable.
3
4

Disconnect the wiring of the feeder.


Cut the wire straps.

rev. 1.0 - 12/2009

5-21

075.1

5
6
7
8
9
10

Service Manual

Remove the wiring from the left-hand inside frame.


Unscrew the drive axle extension (5, LH side). It is left hand threaded.
Remove bushes (2) on both sides from the feeder module.
Remove the plastic clips from the bearing (3) (see detail B).
Hold the feeder module and shift the ball bearings (3) to the inside, out of the side frames
(see detail C).
Lift the axle and remove the feeder in the direction of the big arrow.

Note
In case tension spring (1) is replaced or you do not remember the hook it was attached to: the
normal force of the separation roller with an empty feeder should be between 1.7 N and 2.5 N.
Middle feeder (feeder 2)

7
6
5

LH

1 2 3 4

8 9 10

RH

To loosen the middle feeder:


1
2
3
4
5
6
7
8
9
10
11

Unhook the tension spring (9, see the note on tension springs in Section 5.2.5
(Dis)assembly - Feeders) from the screw (8) (on the right-hand side of the feeder).
Disconnect the wiring of the feeder.
Cut the wire straps.
Remove the wiring from the left-hand inside frame.
Remove the spring clip, clutch (4), belt, and pulley of the middle transportation axle.
Unhook the tension spring (5) from the inside frame.
Remove axle part (6) of the lower transportation axle.
Remove axle (10) to the right-hand side.
Remove sprocket (7).
Remove the guide plate (1).
Remove the screw of the left-hand and right-hand side hinge pin (2) of the middle feeder.

5-22

rev. 1.0 - 12/2009

Service Manual

075.1

RH

LH

To remove the middle feeder:


1
2

Move the feeder a bit downstream (A).


Remove the feeder by turning it out of the machine as indicated (B).

Note
Be careful when replacing feeder 2, the hinge pin at the RH side is locking the ball bearing.
Lower feeder (feeder 1)

6
5

LH

1 2 3 4

7 8 9

RH

To loosen the lower feeder:


1
2

Unhook the tension spring (8, see the note on tension springs in Section 5.2.5
(Dis)assembly - Feeders) from the screw (7) (on the right-hand side of the feeder).
Disconnect the wiring of the feeder.

rev. 1.0 - 12/2009

5-23

075.1

3
4
5
6
7
8
9
10

Service Manual

Cut the wire straps.


Remove the wiring from the left-hand inside frame.
Remove the spring clip, clutch (4), belt (3).
Unhook the tension spring (5) from the inside frame.
Remove axle part (6) of the lower transportation axle.
Remove axle (9) to the right-hand side.
Remove the guide plate (1).
Remove the two screws of the left-hand and right-hand side hinge pin (2) of the lower
feeder.

To remove the lower feeder:


1
2

Move the feeder as far as possible downstream (A).


Remove the feeder by turning it out of the machine as indicated (B).

RH

LH

Note
Be careful when replacing feeder 1, the hinge pin at the RH side is locking the ball bearing.

5-24

rev. 1.0 - 12/2009

Service Manual

075.1

Automatic separation feeder (with daily mail)


This section describes the replacement of the rollers and pulleys of the feeder. For several
replacements it is necessary to remove some covers above or below the feeders. The removal
of these covers is shown in the following figure.

1
2

3
4

5
6

LH

RH

To remove cover 1 to 4:
1
2
3
4
5
6

Remove the screws on the right-hand side. To remove cover 1, its necessary to remove the
top cover first (see Section Top cover feeders, covers collator area, power supply cover
on page 5-9).
Pull cover 1, 2 and 3 backwards on the right-hand side and pull it out on the left-hand side.
Loosen the screws (6) at cover 5.
Remove the cover.
Pull cover 4 backwards on the right-hand side.
Pull it out on the left-hand side.

rev. 1.0 - 12/2009

5-25

075.1

Service Manual

Rubber paper pullers

RH

LH

1 2 3 4 5

Note
In case of the high capacity feeder remove the cover plate from the feeder module to get
access to the feed axle assy.
To remove the rubber paper pullers (all feeder types):
1
2
3
4
5
6

Remove bracket (5) from the right-hand side of the feeder module.
Remove the feed axle assy. (2) in the right-hand side direction (A) until the left-hand side
is clear from the axle (1).
Tilt the axle assy. (2) at the left-hand side (B) and withdraw the right-hand side of the axle
from the hole in the feeder frame.
Remove the axle assy. as indicated (C).
Hold the plastic cover (3) in place with one hand and push firmly against the rubber paper
puller as indicated (D).
Rotate the axle 180 degrees and push again. Repeat the rotating and pushing until the
paper puller can be pulled of the axle.

Note
Ensure on replacement that the plastic cover is replaced below the ridge (3) on the paper guide
and that the feeder assy. is correctly fitted onto the axle. Ensure that the belt runs across the
pulleys.

5-26

rev. 1.0 - 12/2009

Service Manual

075.1

Pulley of paper puller axle

RH

LH

To remove the pulley from the paper puller axle:


1
2

Remove the feed axle assy. as described in Section Rubber paper pullers.
Release the assy. (1) from the plastic cover and remove it.

Upper separation roller


Note
The feeder unit does not need to be removed for replacing separation rollers.

Grease

RH
Push

LH
2
To remove the upper separation roller:
1
2
3
4
5
6
7

Remove the feed axle assy. as described in Section Rubber paper pullers on page 5-26.
Click the plastic cover (2) off the axle (A).
Remove it with the belt and the paper pulleys from the feed axle.
Remove the grease from the left hand side of the feed axle with some alcohol.
Push the feed roller (1) to the left hand side of the axle as indicated.
Rotate the axle 180 degrees and push again.
Repeat the rotating and pushing until the feed roller can be pulled of the axle.

rev. 1.0 - 12/2009

5-27

075.1

Service Manual

Note
Before replacing the feed roller, ensure that the axle is free of grease. After replacing the feed
roller, put some grease Molykote PG 65 on the plastic cover (2) as shown in the previous
figure. Replace the plastic cover with the belt and the rollers.
Lower separation roller
Note
The feeder unit does not need to be removed for replacing separation rollers. In case of a high
capacity feeder remove the front plate to get access to the lower separation roller. To remove
this front plate, loosen (but not remove) the screw that holds the plate.
When you replace the plate, the daily mail switch should point to auto, not to daily mail.

RH

LH
To remove the lower separation roller:
1
2
3
4

Remove cover 3 as described in Section Automatic separation feeder (with daily mail) on
page 5-25.
Remove bracket (3) from the right-hand side of the feeder module.
Move the separator axle assy. (2) in the right-hand side direction (A) until the left-hand side
is clear from the hinge plate (1).
Move the axle assy. (2) downwards side and withdraw the right-hand side of the axle from
the hole in the feeder frame.

5-28

rev. 1.0 - 12/2009

Service Manual

075.1

Slide the roller (1) of the axle assy. (2) as shown in the following figure.

RH

LH
Note
Before replacing the feed roller, ensure that the axle is free of grease.
Gears
For the removal of the gears at the left-hand side of the feeder it is not necessary to remove the
feeder from the machine.
The gear 48T can be removed after the extension axle with the pulley etc. has been removed.
1
2
3

Remove the spring clip securing the gear 64T.


Lift the feeder.
Slide the gear 64T of the axle.

rev. 1.0 - 12/2009

5-29

075.1

5.2.6

Service Manual

(Dis)assembly - Vertical transport

To get access to several parts of the vertical transport track, remove the vertical transport cover
as described in Section Covers upper unit on page 5-10.

5-30

rev. 1.0 - 12/2009

Service Manual

5.2.7

075.1

(Dis)assembly - Collating area

LH
The parts which are described in this section are located in the upper arm of the collating area.
It is recommended to remove the complete collating arm.
1
2
3

Remove the collator area covers as described in Section Top cover feeders, covers collator
area, power supply cover on page 5-9.
Disconnect the wiring of the collator motor.
Loosen the set screw (6) on the bush (7) as shown in the following figure.

LH

4
5

Pull the motor outside the frame.


Support the collating arm.

rev. 1.0 - 12/2009

5-31

075.1

6
7

Service Manual

Remove the screws (1) as shown in the previous figure (two at the left-hand side and two
at the right-hand side).
Carefully remove the collating arm.

Collator stops

RH

LH

To remove the collator stop motor:


1
2
3
4
5

Remove the plate with clips attached (1).


Remove the moving arm (2).
Remove the gear wheel (3).
Disconnect the collator stop motor wiring.
Remove the two screws (4) that hold the collator stop motor in place, and carefully remove
the motor (5).

5-32

rev. 1.0 - 12/2009

Service Manual

075.1

Belts
8

10

RH

7 6

LH

Transportation belts
The transportation belts are only available as a set. If a belt is worn, all the belts should be
replaced.
1
2
3
4
5

Remove roller (1) from the axle.


Slide the axle to the left-hand side out of the bearings. Take care of the tensioner (2), it is
spring loaded.
Remove the tensioner (2).
Remove the plate (3).
Remove the axles (4 and 5).

The middle transportation belt can now be replaced.


Guide rollers
The guide rollers (8 and 10) are spring loaded.
1
2
3
4
5
6

Remove the accompanying spring clips and washers.


Slide the guide rollers of the axles.
Remove the screw of the axle of the guide roller (9).
Slide the axle to the left-hand side.
Remove the spring clip at the right-hand side of the guide roller.
Slide the roller of the axle.

rev. 1.0 - 12/2009

5-33

075.1

5.2.8

Service Manual

(Dis)assembly - Folder

Right-hand drive mechanism


Lower folder section

RH
4

Belts:
The removal of the drive belt (1) as described in Section Drive mechanism right-hand - Belts
and pulleys on page 5-15.
Pulleys:
1
2
3
4

Remove the drive belt (1).


Remove the accompanying spring clip.
Remove the clamping ring.
Slide pulley 2 and 3 of the axles.

5-34

rev. 1.0 - 12/2009

Service Manual

075.1

Gears:
The gears, number 4 (picture on page 5-34) and number 1 (following picture), can easily be slid
of the axles. Take care of the cyl. pins when removing the gears.

RH

rev. 1.0 - 12/2009

5-35

075.1

Service Manual

Upper folder section

RH

1
2

5
8

Belts:
1
2

Slacken the two screws (2) of the belt tensioner (1).


Remove the belt (4) from the pulleys (3 and 5).

Pulleys:
1
2
3
4

Remove the belt (4) as described in the previous section.


Remove the spring clip and the bush of the pulley (3).
Slide the pulley (3) of the axle.
Slide the pulley (5) of the axle.

Gears 6 and 8:
1
2

Remove the spring clip, clamping ring and washers.


Remove the gears (6 and 8). When removing gear 6, take care of the cyl. pin.

Gear 7:
1
2
3

Remove the belt (4).


Remove the pulley (5).
Remove gear (7).

5-36

rev. 1.0 - 12/2009

Service Manual

075.1

Left-hand drive mechanism


Gears

LH
5

To remove the gears of the lower folder section (1 to 5) at the left-hand side of the machine:
1
2
3

Remove the circuit board.


Remove the spring clips, clamping rings and washers. Take care of the cyl. pin of the gears
1, 3 and 5 and the spacers of the gears 2 and 4.
Remove the gears (1 to 5).

rev. 1.0 - 12/2009

5-37

075.1

Service Manual

Fold mechanism

12

4 5

RH

10
11
12

13
14

17

16

15

The fold plates (1 and 5) are driven via the curved gears (7, four in total) and two gears (3),
activated by the two clutches (2) on the drive axle (4).
Gears 32T, drive axle
1
2
3
4

Remove the belt (13), pulleys (12 and 14) and freewheel clutch (11).
Remove the locking plate (10) securing the bearing of the drive axle (4).
Carefully move the axle (4) to the right-hand side until the bearing clears the frame.
Carefully lift the axle assembly as far upwards as possible. Take care of the wiring of the
clutches on the axle and the plastic bearing on the left-hand side.

5-38

rev. 1.0 - 12/2009

Service Manual

LH

5
6

075.1

RH

Remove the bearing, spacer, washers and the spring clip of the left-hand side of the drive
axle assembly.
Slide the gear (1) of the axle.

To remove the gear (4) and clutches (2 and 3):


1
2
3
4
5

Cut the wire straps at the connectors of the clutches.


Slide the clutch (2) to the left-hand side of the axle. Take care of the cyl. pin of the clutch.
Remove all the components between the clutches, including the cyl. pin of the clutch (3).
Slide the clutch (3) to the left-hand side of the axle.
Remove the gear (4) from the drive axle.

Note
Ensure on replacement to secure the wiring of the clutches again and that both clutches are
retained by the locking plate. Also ensure that the clutches clockwise and counterclockwise are
placed in the proper position.

rev. 1.0 - 12/2009

5-39

075.1

Service Manual

Curved folder gears


1
2
3

Remove the drive axle assembly as described in Section Gears 32T, drive axle on page 538 (refer to the picture on the same page).
Remove the bearings (9) from the axles (6).
Remove the brake discs (15, spring loaded), the springs, the brake strip (16) and the
bearings (17) from the axles (8).

7 8

1 2 3 4 5 6

22 21 20

LH

12 11 10 9

19 18 17 16 15 14 13

4
5
6
7
8
9
10

Remove the levers for the flap actuators, the bearings, etc. (1 up to 6) from the axles (12).
Pin 6 has to be loosened by a set screw, to be accessed at axle end (12).
Remove the brackets (7) with the sensors.
Remove the brake discs with the bearings (20 up to 22) from the axles (13).
Remove the screws at the left and right-hand side of the guide plate (9)
Unhook the guide plate and remove it.
Remove the screws at the left and right-hand side by which the brackets (10) are mounted
to the upper frames.
Carefully lift each complete fold assembly upwards and withdraw it.

5-40

rev. 1.0 - 12/2009

Service Manual

075.1

First curved folder gears

RH
3

4 5

LH

7
6

9 10

RH
11 12

13 14 15

LH
17
16

To remove the curved gears:


1
2
3

Remove the two screws (6).


Slide both hinge plates (5 and 7) together with the fold plate (4) of the axle.
Pull the curved gears (2 and 8) of the axle.

rev. 1.0 - 12/2009

5-41

075.1

Service Manual

Second curved folder gears


Refer to the figure on page 5-41.
1
2

Remove the hinge plates (15 and 17) in the same way as described previously.
Pull the curved gears (9 and 10) of the axle.

Note
Ensure on replacement that the curved gears and the curved discs are replaced correctly onto
the axle (refer to the following figure). Secure the wiring of the clutches again. The right hand
curved gear is marked with an R and the left-hand curved gear is marked with an L.

Wrong

curved disc

curved gear

spring lever

Right

Note
After replacing and securing the complete fold assembly, check the adjustment of the paper
guides (3 and 11, refer to the figure on page 5-41). See Section Paper guide on page 5-93.

5-42

rev. 1.0 - 12/2009

Service Manual

075.1

Rollers
Input rollers
Remove the drive belt as described in Section Drive mechanism right-hand - Belts and pulleys
on page 5-15.

LH
1
2

RH

3
To remove the input rollers:
1
2

Remove the pulley, the gears of the upper input rollers (1) and the gears of the lower input
rollers (2) as described in Section Right-hand drive mechanism on page 5-34.
Remove the bearing locking plate (3).

rev. 1.0 - 12/2009

5-43

075.1

Service Manual

2 3

RH

6
7

LH
3
4
5
6
7
8
9

Remove the gear 7 of the lower input roller (6).


Remove the bearing locking plate (5).
Remove the guide strip (4) and the guide bracket below it.
Move the upper input roller (2) to the right-hand side until the left-hand bearing is free of
the left-hand inside frame.
Lift the left-hand side of the roller upwards and withdraw the roller out of the right-hand
inside frame.
Move the lower input roller (6) to the right-hand side until the left-hand bearing is free of
the left-hand inside frame.
Lift the left-hand side of the roller upwards and withdraw the roller out of the right-hand
inside frame.

5-44

rev. 1.0 - 12/2009

Service Manual

075.1

Lower fold rollers


1

Remove the gears (8, refer to the previous figure).

40

"
2
3
4
5
6
7

Loosen the two hexagonal head screws (3).


Push down the solenoid (4) to get access to the screw (2).
Remove the screws (2).
Remove the bearing plate (1).
Move the roller to the right-hand side until the left-hand bearing is free of the left-hand
inside frame.
Lift the left-hand side of the roller upwards and withdraw the roller out of the right-hand
inside frame.

Note
After replacing the lower fold rollers, check the adjustment of the solenoid. See Section
Solenoids on page 5-94.

rev. 1.0 - 12/2009

5-45

075.1

Service Manual

Upper fold rollers

RH

"

LH

To remove the upper fold rollers:


1
2
3
4
5

Remove the belt with the pulley (5) and the three gears (4) at the right-hand side.
Remove the guide strip (2). This is necessary for the removal of the first fold roller.
Remove the bearing locking plates (3) on both sides.
Move roller 1 to the right-hand side until the left-hand bearing is free of the left-hand frame.
Move the left-hand side of the roller downwards and withdraw the roller out of the righthand frame.

Note
For belt adjustments, see Section Drive belt upper folder section. page 5-92.

5-46

rev. 1.0 - 12/2009

Service Manual

5.2.9

075.1

(Dis)assembly - Main drive mechanism inserter

RH
8

76

The main motor 8 provides the mechanical power to the 075.1, with exception of the collating
area and the collator stops.
Belts
PJ-belt
For removal of the PJ-belt (2):
1
2
3

Disassemble the main drive belt for the feeder and folder section. See Section Drive
mechanism right-hand - Belts and pulleys on page 5-15.
Loosen the two hexagonal head screws (4) of the tensioner (5).
Remove the belt (2) from the main pulley (1) and the motor pulley (3).

rev. 1.0 - 12/2009

5-47

075.1

Service Manual

Drive belt inserter

12

RH

14

13 12 11

10

All moving components of the inserter part are driven by belt 10. To remove belt 10:
1
2

Loosen the two hexagonal head screws of the tensioner (1).


Remove the belt from the pulleys.

5-48

rev. 1.0 - 12/2009

Service Manual

075.1

Belt envelope feed

"

&

'




40


!
"

  ' & %

$ #

To remove the belt envelope feed:


1
2

Remove the support plate (11) by which the intermediate axle (13) is supported. Take care
of the bearings and the washers.
Remove the belt (5) from the pulley on the intermediate axle and from the pulley on the
envelope feed axle (3).

Pulleys
Refer to the figure on page 5-48.
Pulleys 5 and 9
1
2

Remove the spring clips of the pulleys (5 and 9).


Remove the pulleys (5 and 9).

Pulley 11
1
2

Remove the main pulley (Refer to Section Drive mechanism right-hand - Belts and pulleys
on page 5-15).
Remove the pulley (11).

rev. 1.0 - 12/2009

5-49

075.1

Service Manual

Pulley 8
1
2
3

Remove the mounting plate (6) with the adjustment plate and the pulse disc sensor.
Remove the pulse disc (7).
Slide the pulley (8) of the axle. Take care of the spacer.

Note
After replacement of the pulse disc sensor be sure that it clears the pulse disc on both sides.
Refer to the figure on page 5-49.
Pulley 9
1
2
3

Remove the belt (5) as described in Belt envelope feed on page 5-49.
Remove the accompanying spring clip and washer from the pulley (9).
Slide the pulley (9) of the envelope feed axle (3).

Pulley 14
1
2
3

Remove the bearings, washers and gears from the intermediate axle (13).
Tap the tension pin from the intermediate axle.
Slide the pulley (14) of the axle.

Gears
Refer to the figure on page 5-48.
Gears 3 (sealing rollers)
1
2
3

Remove the pulley (5).


Remove the spring clips and washers.
Slide the gears (3) of the axles.

Gear 2
The gear (2) is mounted to the axle by a tension pin. To remove the gear (2):
1
2
3
4
5
6

Remove the tension springs of the bearings of the axle.


Remove the spring clip with washer and bearing at the left-hand side of the axle.
Slide the two rollers to the right-hand side.
Remove the cyl. pin from the axle.
Slide the axle with the gear (2) to the right-hand side out of the right-hand inside frame.
Tap the tension pin to remove the gear (2).

Gear 4
The gear (4) is mounted to the pulse disc axle (14) by a tension pin. To remove the gear (4):
1
2
3
4
5
6
7

Remove the pulse disc (7) and the pulley (8).


Remove the spring clip at the left-hand side of the axle.
Slacken the set screws of the two rollers.
Remove the locking plate (13).
Slide the pulse disc axle (14) to the right-hand side out of the right-hand inside frame. While
doing this: remove the bearing, the washer, and the two rollers.
Tap the tension pin.
Dissemble the gear.

Gear 12
1
2

Remove pulley (9).


Slide the gear (12) of the axle.

5-50

rev. 1.0 - 12/2009

Service Manual

075.1

Refer to the figure on page 5-49.


Gears 8, 10, 15, 16, 18, 20 and 22
1
2

Remove the spring clips and washers.


Remove the gears (8, 10, 15, 16, 18, 20 and 22).

Gear 21
1
2
3

Remove the nuts. Take care of the tension spring.


Slide all the parts of the brake rod.
Remove the gear (21).

For adjustment of the friction brake, see Section Friction brake on page 5-97.
Gear 6
1
2
3
4
5
6

Remove the gear (8).


Dissemble the clutch (7).
Remove the support plate (11).
Disconnect the wiring of the clutch.
Slide the clutch of the axle.
Remove gear 6.

Gears 4 and 12
1
2
3

Remove the support plate (11) to free the intermediate axle (13) with its components.
Remove the bearings, washers and spring clip from the axle.
Slide the gears (4 and 12) from the axle.

Gear 17
1
2
3
4
5
6

Remove the insert table to get access to the transportation axle.


Remove the spring clip, washer and bearing at the left-side of the transportation axle (2).
Move the axle a little to the right-hand side.
Slide the gear (17) to the left-hand side.
Remove the cyl. pin.
Slide the gear (17) of the axle.

Gear 19
The gear (19) is mounted to the transportation axle (1) by a tension pin. To remove this gear:
1
2
3
4
5
6

Remove the insert table.


Remove the spring clip, washer and bearing from the left-hand side of the axle.
Slide the rollers to the right-hand side to remove the cyl. pins.
Slide the axle to the right-hand side out of the right-hand inside frame. Take care of the
two rollers.
Tap the tension pin.
Remove the gear (19) from the axle.

Clutches
Slip clutch envelope feed axle
Refer to the figure on page 5-49.
1
2
3
4

Remove the metal ring of the pulley (9).


Slide the belt (5) of the pulley (9).
Remove the pulley from the axle.
Slide the slip clutch of the axle.

rev. 1.0 - 12/2009

5-51

075.1

Service Manual

Clutch CW
When the machine is switched on the gear (6) it is constantly driven. By activating the clutch
(7) all the gears shown in the figure on page 5-49 and the accompanying axles and rollers of
the envelope feed and envelope track will be driven. So to feed, open and place an envelope on
the insert table the clutch (7) is activated.
To remove the clutch (7):
1
2
3

Remove the support plate (11) and the gear (8).


Disconnect the wiring of the clutch.
Slide the clutch (7) of the axle.

5-52

rev. 1.0 - 12/2009

Service Manual

075.1

Power supply assy. and main motor (M2)


Note
The main fuse can be replaced without removal of the covers.
In the switch mode power supply (6) an extra fuse is present.
Power supply assy.
1

LH

To remove the power supply assy.:


1
2
3
4

Remove the main lead.


Remove the power supply cover (2).
Disconnect all wiring.
Cut the wire straps.

LH
5
6

Remove the two countersunk head screws (4) and the two round head screws (7) securing
the power supply assy.
Pull the power supply assy. out of the machine.

rev. 1.0 - 12/2009

5-53

075.1

Service Manual

Note
When replacing the power supply assy., ensure that the guide plates 1 (refer to the figure on
page 5-53) are fitted correctly in the guide rollers. Also take care to fit the microswitch
correctly and ensure the correct functioning.
Main motor M2

RH
8

76

To remove the main motor:


1
2
3
4
5

Release the belt tensioner (5)


Remove the belt (2).
Remove the bottom plate of the machine.
Remove the four screws (6) and the washers (7).
Withdraw the motor (8) from the machine. Take care of the wiring.

Note
For belt adjustment, see Section Main drive PJ-belt on page 5-88, and Section Main drive
belt inserter on page 5-90.

5-54

rev. 1.0 - 12/2009

Service Manual

075.1

5.2.10 (Dis)assembly - Envelope hopper


Remove the feed platform

1
2
3
4
5

Move the side guides as wide as possible.


Remove the two countersunk screws (2) securing the rear cover (3).
Move the side guides a bit to the middle.
Remove the round head screws (6) securing the feed platform (1) on both sides to the inside
frames (5).
Lower the rear side of the feed platform downwards and withdraw it in the rear side
direction. Take care of the rear cover.

Remove the rear cover


1
2

Remove the feed platform as described in section Remove the feed platform on
page 5-55.
Pull the rear cover (3) downwards from behind the frame rod (4) and withdraw it in the rear
side direction (part numbers according to figure on page 5-55).

rev. 1.0 - 12/2009

5-55

075.1

Service Manual

O-rings

8 9 10 11

2 3 4 5

6 7

Removal
1
2
3
4
5

Remove the feed platform (see Remove the feed platform on page 5-55).
Remove the spring clips, washers, bearings, etc. (1) from both sides of the feed shaft (5).
Shift the feed shaft in the right-hand side direction until it clears the LH inside frame.
Tilt the left-hand side of the feed shaft in the rear side direction and when possible withdraw
it in the left-hand side direction.
Push the O-rings (2) from the two joggers (3) and remove them from the feed shaft.

Rollers
Separation roller, removal
Note
Before removing the separation roller, first check the adjustment procedure as described in
section Separation roller on page 5-96.
1
2
3
4
5
6
7

Pull down the envelope separation lever.


Slacken the two set screws (7) of the feed roller (6) (part numbers according to figure on
page 5-56).
Slide the feed roller in the left-hand side direction against the jogger (3).
Remove the round head screw (9).
Loosen set screw (8).
Withdraw the rod (11) with the separation roller (10).
Slide the separation roller from the rod.

5-56

rev. 1.0 - 12/2009

Service Manual

075.1

Feed roller, removal


1
2
3
4
5
6

Remove the feed shaft as described in section O-rings on page 5-56.


Push the O-ring (4) from the jogger (3) and remove it from the feed shaft (5).
Slacken the set screw of the jogger.
Slide the jogger from the feed shaft.
Slacken the two set screws (7) of the feed roller (6).
Slide the feed roller from the feed shaft.

Feed roller, replacement


1
2

Position the feed roller in the middle of the feed shaft and the removed jogger at the same
distance from the feed roller as the other jogger.
Ensure that the set screws of the feed roller and the jogger are tightened onto the flattened
part of the feed shaft.

rev. 1.0 - 12/2009

5-57

075.1

Service Manual

Envelope track
Lower rollers

1 2 3 4 5

RH

LH

13 12 11 10

1
2
3
4
5

Remove the bottom plate.


Remove the spring clip, washer and bearing (spring loaded) from the axle of the first set of
the rollers (13).
Move the axle to the left-hand side to free the cyl. pins.
Remove the cyl. pins.
Lift the axle and slide the rollers of the axle. Take care of the pressure spring of the
bearings.

Note
Remove the second set of rollers (12) in the same way.
Remove the inner two rollers in the same way.
To remove the third set of rollers (11), first remove the outer two rollers (10).

5-58

rev. 1.0 - 12/2009

Service Manual

075.1

RH

2 3 4 5 6 7 8 9 1011

12
13
14

22
21
LH

18 17 16 15
20 19
6
7
8
9
10

Remove the flap scraper (21).


Remove the pressure springs (15) of the bearings of the fourth set of rollers (19).
Slide the rollers to the left-hand side to remove the cyl. pin.
Remove the spring clips.
Slide the axle to the right-hand side and remove the rollers (19) from the axle.

Note
For adjustments of the flap scraper, see Section Flap scraper on page 5-98.

rev. 1.0 - 12/2009

5-59

075.1

Service Manual

Upper rollers
Refer to the figure on page 5-58.
1
2
3
4
5
6

Remove the insert table as described in Section 5.2.12 (Dis)assembly - Envelope


transport on page 5-69.
Slide the first set of rollers (5) of the axle (7).
Remove the cyl. pins (4).
Remove the spring clip (1), washer (2) and bearing (3) at the left-hand side of the axle (7).
Slide the axle to the right-hand side.
Remove the rollers from the axle.

Note
Remove the second and third set of rollers in the same way.
Refer to the figure on page 5-59.
1
2
3
4
5
6

Remove the insert table to get access to the fourth set of rollers of the envelope track.
Remove the fixing plate envelope track (8, figure on page 5-58) to get more room.
Slide the rollers (10) aside to remove the cyl. pins.
Remove the spring clip, washer and bearing at the left-hand side of the axle.
Slide the axle to the left-hand side.
Remove the rollers from the axle.

Rubber roller
Refer to the figure on page 5-59.
1
2
3
4
5
6
7

Remove the insert table and the transportation table (19 in figure on page 5-69).
Slide the transportation table in the direction as indicated, over the second fold roller.
Remove the knob (1) and the spring clips (5) of the rubber roller (11).
Remove the gear at the right-hand side of the rubber roller as described in Section Gears
on page 5-50.
Slide the roller to left-hand side to free the right-hand side of the rollers from the right-hand
inside frame. Take care of the bearing.
Lift the right-hand side.
Withdraw the rubber roller from the machine.

5-60

rev. 1.0 - 12/2009

Service Manual

075.1

Finger solenoid

RH

1
2
3
4

Remove the draw bar (3).


Remove the tension spring (4).
Disassemble the mounting bracket (2) with the solenoid (1).
Remove the solenoid (1) from the bracket (2).

Note
For adjustments of the solenoid, see Section Solenoids on page 5-94.

rev. 1.0 - 12/2009

5-61

075.1

Service Manual

5.2.11 (Dis)assembly - Upper unit


Drive mechanism
The drive mechanism of the upper unit is located at the right-hand side of the machine.

1
2
3

4
5
6

7
8

Belt
1
2

Slide the belt (7) of the pulley (6).


Remove the belt from pulley (8).

Pulleys
Pulley 8:
1
2

Remove the spring clip of the pulley (8).


Slide pulley (8) from the axle.

5-62

rev. 1.0 - 12/2009

Service Manual

075.1

Pulley 6:
1
2

Remove the spring clip and washer.


Slide pulley/gear (6) from the axle.

Gears
Gear 6:
See the previous section (pulley (6)).
Gear 5:
1
2
3
4
5
6
7
8
9
10

Open the upper unit.


Remove the six screws by which the brake plate (1) is mounted to the upper frames. Take
in account the weight of the upper unit when removing the dampers.
Close the upper unit and remove the axle (2).
Move the brake plate (1) with assembled components carefully aside. Take care of the
wiring to the solenoid, the sensor and display.
Remove the plate (3).
Remove the spring clips of the axle (4).
Remove the cyl. pins of the rollers.
Slide the axle (4) to the right-hand side out of the frame.
Tap the tension pin of the gear (5).
Slide the gear (5) of the axle.

Document inserting

RH

LH
12

11

10

Rollers
1
2
3

Remove the guide plates (1) and (4) on both sides.


Slide the upper insert rollers (2) of the axle. Take care of the cyl. pins.
Slide the first set of ejection rollers (12) of the axle. Take care of the cyl. pins.

rev. 1.0 - 12/2009

5-63

075.1

Service Manual

RH

LH

To remove the second set of ejection rollers:


1
2
3
4
5

Remove the spring clip (5).


Remove the roller (4) from the axle.
Remove the spring clip (2).
Slide the axle to the left-hand side.
Tap out the cyl. pin of the roller (1) and slide the roller from the axle.

Gears
Refer to the figure on page 5-63.
1
2
3
4
5
6

Remove the guide plates (1) and (4) on both sides.


Remove the bracket (6) and the sensor. Take care of the wiring of the sensor.
Remove the pulley (5) and the spring clip (10).
Slide the outer bearings from the axle (8).
Remove the tension springs (3).
Slide the axle (8) with complete insert assembly through the slotted holes out of the frames.

5-64

rev. 1.0 - 12/2009

075.1

8
7

10

11

LH

RH

Service Manual

Refer to the figure above.


1
2

Remove the frame plate (5).


Slide the gears (4, 7 and 8) of the axles. Take care of the pressure springs (6).

rev. 1.0 - 12/2009

5-65

075.1

Service Manual

Refer to the figure on page 5-63.


1
2

Remove the screws (7).


Withdraw the complete ejection assembly (9) together with the draw bar and the attached
plunger (1, figure on page 5-65), from the frames. Take care of the washers and the
pressure spring of the plunger.

Refer to the figure on page 5-65.


1
2

Remove the frame plate (9).


Slide the gears (10 and 11) from the axles.

Ejection solenoid
Refer to the figure on page 5-65.
1
2
3
4

Remove the covers of the loc, to get access to the solenoid. See Section Right-hand side
cover on page 5-7.
Disconnect the wiring of the solenoid.
Remove the two screws (3).
Remove the solenoid (2). Take care of the plunger (1), the washers, and the pressure
spring.

Note
For adjustments of the solenoid, see Section Solenoids on page 5-94.

5-66

rev. 1.0 - 12/2009

Service Manual

075.1

rev. 1.0 - 12/2009

5
4

LH

RH

Envelope transport and sealing

5-67

075.1

Service Manual

Rollers
Sealing transport rollers
1
2
3

Open the upper unit.


Remove the spring clips of the axle (6).
Slide the transport rollers (4) of the axle. Take care of the pressure springs (5).

Lower reverse rollers


Refer to Section Pulleys on page 5-62.
Upper reverse rollers
1
2

Remove the accompanying spring clips and washers.


Slide the rollers (7) of the axle.

Sealing solenoid
1
2
3

Disconnect the wiring of the solenoid (1).


Remove the screws (2).
Withdraw the solenoid. Take care of the pressure spring and the washers at the plunger.

Note
For adjustments of the solenoid, see Section Solenoids on page 5-94.
Brush solenoid removal

1
1
2
3

Disconnect the wiring of the solenoid (2).


Remove the screws (1).
Withdraw the solenoid. Take care of the spacer and plunger.

5-68

rev. 1.0 - 12/2009

Service Manual

075.1

LH

1 2

22 21

20 19

18 17

5 6 7

8 9 10 11 12

13

14 15 16

RH

5.2.12 (Dis)assembly - Envelope transport

Lower ejection rollers


1
2

Remove two screws (13) of the insert table (19) and four screws (1) of the guide plate (2).
Remove the drive belt inserter as described in Section Drive belt inserter on page 5-48.

rev. 1.0 - 12/2009

5-69

075.1

3
4
5
6
7
8
9

Service Manual

Remove the locking plate of the bearing at the right-hand side of the transportation axle
(20).
Slide the axle (20) to the right-hand side.
Remove the cyl. pin (17).
Slide the roller (18) from the axle.
Remove the spring clip, washer and bearing from the left-hand side of the axle (22).
Slide the axle to the right-hand side.
Slide the rollers (21) from the axle.

Sealing track transportation rollers


Refer to Section Pulleys on page 5-49 and to the figure on page 5-48.
1
2

Remove the pulse disc (7).


Remove the pulley (8) from the pulse disc axle (14).

Refer to the figure on page 5-69.


1
2
3
4

Remove the pressure springs (16) from the bearings (15) of the axle (8).
Slide the rollers (4) aside to remove the cyl. pins (3).
Remove the spring clip, washer and bearing at the left-hand side of the axle.
Slide the rollers of the axle.

Note
Take care of the pressure springs (16) when replacing again. On the left-hand side a spring
with lower force than on the right-hand side has to be fitted.
5.2.13 (Dis)assembly - Envelope sealing and ejection
Upper sealing roller
Refer to the figure on page 5-69.
1
2
3
4

Remove the gear at the right-hand side of the sealing roller (6). Refer to Section Gears
on page 5-50.
Remove the pressure springs (11) from the bearings (12) and the spring clip at the lefthand side of the sealing roller. Take care of the washer (10) and the spring (9).
Move the sealing roller (6) to right-hand side to free the left-hand bearing from the lefthand inside frame.
Withdraw the upper sealing roller.

Lower sealing roller


Refer to the figure on page 5-69.
1

Remove the upper sealing roller. Refer to the previous section.

Remove the gear at the right-hand side of the sealing roller (5). Refer to Section Gears
on page 5-50.
Remove the two screws (14) and the mounting plate (7).
Remove the spring clip, washer and bearing at the left-hand side of the lower sealing roller
(5).
Move the sealing roller to the right-hand side.
Withdraw the lower sealing roller.

2
3
4
5

5-70

rev. 1.0 - 12/2009

Service Manual

075.1

5.2.14 (Dis)assembly - Sensors


Safety switches
Upper unit safety switch

RH

The safety switch of the upper unit is located at the right-hand side of the machine near the
lowest feeder. To remove the upper unit safety switch:
1
2
3
4

Remove the right-hand side cover.


Cut the wire strap.
Remove the bracket (2) together with the safety switch (1).
Remove the safety switch from the bracket.

rev. 1.0 - 12/2009

5-71

075.1

Service Manual

Safety switch LH side cover

LH
1

The safety switch is located at the left-hand side of the machine near the sealing rollers. To
remove the safety switch (3):
1
2
3

Open the left-hand side cover.


Remove the cover (1).
Remove the safety switch (3) from the bracket (2).

5-72

rev. 1.0 - 12/2009

Service Manual

075.1

Safety switch collator area

RH

The safety switch is located at the right-hand side beneath the collator area and behind the
supply cover. To remove the safety switch (2):
1
2

Remove the supply cover.


Remove the safety switch (2) from the frame (1).

rev. 1.0 - 12/2009

5-73

075.1

Service Manual

Sealing liquid reservoir switch

1
1
2

Remove screws (2).


Remove the bracket (1) from the frame.

5-74

rev. 1.0 - 12/2009

Service Manual

075.1

DFC and photocells


Note
Whether or not photocells are replaced, it is advised to reset the photocells after finishing
servicing.
Feeder DFC
1

RH

LH
Each feeder is equipped with a DFC. To remove the DFC:
1
2
3
4

Remove the covers (1, 2, 3 and 4). Refer to Section Automatic separation feeder (with
daily mail) on page 5-25.
Remove the guide plate (5), when removing the DFC of the middle feeder. Refer to Section
Middle feeder (feeder 2) on page 5-22.
Disconnect the wiring of the DFC.
Remove the screw (2) securing the DFC (3) to the bracket (1).

rev. 1.0 - 12/2009

5-75

075.1

Service Manual

Feeder photocell

2 1

RH
4 3

LH

Transmitter (LED)
1
2
3

Remove the bracket (4) with the transmitter (3).


Disconnect the transmitter.
Remove the transmitter from the bracket.

Receiver (Sensor)
1
2

Disconnect the sensor (1).


Remove the sensor from the bracket (2).

5-76

rev. 1.0 - 12/2009

Service Manual

075.1

Vertical track photocell

Transmitter (LED)
1
2
3
4

Open the loc.


Remove the guide plate (1) with the assembled transmitter (2).
Disconnect the wiring of the transmitter.
Remove the transmitter.

Receiver (Sensor)
1
2
3
4
5

Remove the vertical transport cover.


Cut the wire strap securing the wiring of the sensor (3) to the bracket (4).
Remove the bracket with the sensor.
Disconnect the wiring.
Remove the sensor.

rev. 1.0 - 12/2009

5-77

075.1

Service Manual

Collating area slotted photocell

LH
1
2

Remove the set screw (1) and the pulse disc.


Remove the slotted photocell (2).

Note
Ensure on replacement that the pulse disc sensor clears both sides of the pulse disc.

5-78

rev. 1.0 - 12/2009

Service Manual

075.1

Collating area photocell

2
3

4
5
6
7

RH

LH
Transmitter (LED)
1
2
3
4
5

Move the lower collator arm downwards.


Remove the locking plate of the axle (4) at the right-hand side of the machine.
Free the bearings of the frame.
Remove the hinged guide plate (1) together with the attached sensors (2 and 3). Take care
of the wiring.
Remove the transmitter (3) from the guide plate.

Receiver (Sensor)
1
2

Follow step 1 to 4 of the above procedure.


Remove the sensor (2) from the guide plate.

Folder entry photocell


Transmitter (LED)
1
2
3

Remove the bracket (5) with the transmitter (6) to the left-hand side out of the left-hand
inside frame. Take care of the wiring.
Cut the wire straps.
Remove the transmitter (6) from the bracket.

Receiver (Sensor)
1
2
3

Remove the bracket (5) with the transmitter (6) to the left-hand side out of the left-hand
inside frame. Take care of the wiring.
Cut the wire straps.
Remove the receiver (7) from the bracket.

rev. 1.0 - 12/2009

5-79

075.1

Service Manual

Folder slotted photocell

LH
The sensors are located at the left-hand side of the upper unit. To remove the sensor:
1
2
3
4
5

Open the upper unit.


Remove the bracket (1) with the sensor (2).
Cut the wire strap.
Disconnect the sensor.
Remove the sensor from the bracket.

Note
The sensor (3) can be removed in the same way.

5-80

rev. 1.0 - 12/2009

Service Manual

075.1

Inserter slotted photocell

1
2
3
4

RH
The pulse disc sensor assy. is located at the right-hand side of the machine near the sealing
rollers. To remove the sensor:
1
2
3
4

Remove the pulse disc (4).


Disconnect the wiring of the sensor (2).
Remove the two screws (3).
Remove the sensor.

Note
Ensure on replacement that the pulse disc sensor clears both sides of the pulse disc. To adjust
the position of the sensor, slacken screw (1), reposition the sensor and fasten screw (1).

rev. 1.0 - 12/2009

5-81

075.1

Service Manual

Envelope track photocell

RH

RH

LH
LH

Transmitter (LED)
1
2
3
4
5

Remove the insert table.


Remove the bottom plate.
Pull the air hose connector (4) from the transmitter (3).
Slacken the screw of the transmitter.
Remove the transmitter (3).

Receiver (Sensor)
1
2
3
4
5

Remove the insert table.


Remove the bottom plate.
Remove the bracket (2) together with the sensor (1).
Slacken the screw of the sensor.
Remove the sensor (1).

5-82

rev. 1.0 - 12/2009

Service Manual

075.1

Flap cell

3
4
5

6
Transmitter (LED)
1
2
3
4

Remove the insert table.


Remove the bottom plate.
Remove the bracket (1) with the transmitter (2). Take care of the wiring.
Disassemble the transmitter from the bracket.

Receiver (Sensor)
1
2
3
4
5
6

Remove the insert table.


Remove the bottom plate.
Pull the air hose connector (3) from the sensor (4).
Slacken the screw (6).
Remove the bracket (5) with the sensor (4).
Remove the sensor from the bracket.

rev. 1.0 - 12/2009

5-83

075.1

Service Manual

Insert table photocells

RH

LH

RH

LH

Transmitter (LED)
1
2

Open the upper unit.


Remove the screw (1) to release the transmitter (2).

Receiver (Sensor)
1
2
3
4

Remove the transport table.


Slacken the screw (5).
Remove the bracket (4) with the sensor (3).
Remove the sensor from the bracket. Take care of the wiring.

5-84

rev. 1.0 - 12/2009

Service Manual

075.1

Closer photocell
1

Transmitter (LED)
1
2
3

Slacken screw (4).


Remove bracket (2) with the transmitter (3).
Remove the transmitter from the bracket.

5 6

RH

LH
Receiver (Sensor)
1
2
3
4

Remove the nuts (1 and 7).


Remove the frame (2) complete. Take care of the wiring.
Slacken the screw (3).
Remove the bracket (4) with the photocell (6).

rev. 1.0 - 12/2009

5-85

075.1

Service Manual

Exit photocells

RH

LH
1
2
3

Remove the frame axles (1) together with the cover (2). Take care of the wiring of the
detectors.
Remove the transmitter (LED, 3).
Remove the receiver (sensor, 4).

5-86

rev. 1.0 - 12/2009

Service Manual

075.1

Sealing liquid level sensor

1
1
2

Remove screws (2).


Remove the bracket (1) from the frame.

rev. 1.0 - 12/2009

5-87

075.1

Service Manual

5.2.15 Adjustment
Main drive PJ-belt

10 mm (0.4 inch)
1

The maximum movement of the drive belt at the indicated position is 10 mm (0.4 inch).
To adjust:
1
2
3
4

Slacken the two screws (1) securing the belt tensioner (2).
Shift the belt tensioner to adjust the correct belt movement.
Hold the belt tensioner in position and retighten the two screws.
Check the adjustment and readjust if necessary.

Note
Do not adjust the drive belt too tight.
Note
When adjustment of the belt tensioner is not sufficient, re-adjust the motor position.

5-88

rev. 1.0 - 12/2009

Service Manual

075.1

Main drive belt feeders/folder

10 mm (0.4 inch)

The maximum movement of the drive belt at the indicated position is 10 mm (0.4 inch).
To adjust:
1
2
3
4

Slacken the two screws (1) securing the belt tensioner (2).
Shift the belt tensioner to adjust the correct belt movement.
Hold the belt tensioner in position and retighten the two screws.
Check the adjustment and readjust if necessary.

Note
Do not adjust the drive belt too tight.

rev. 1.0 - 12/2009

5-89

075.1

Service Manual

Main drive belt inserter

10 mm (0.4 inch)

The maximum movement of the drive belt at the indicated position is 10 mm (0.4 inch).
To adjust:
1
2
3
4

Slacken the two screws (1) securing the belt tensioner (2).
Shift the belt tensioner to adjust the correct belt movement.
Hold the belt tensioner in position and retighten the two screws.
Check the adjustment and readjust if necessary.

Note
Do not adjust the drive belt too tight.

5-90

rev. 1.0 - 12/2009

Service Manual

075.1

RH drive belts
Note
The adjustment of the lower and upper drive belt is similar.

upper drive belt

3
2
1

5 mm (0.2 inch)
lower drive belt

The maximum movement of the drive belts (1) at the indicated position is 5 mm (0.2 inch).
To adjust:
1
2
3
4

Slacken the hexagonal head screw (3) securing the belt tensioner (2).
Shift the belt tensioner to adjust the correct belt movement.
Hold the belt tensioner and retighten the hexagonal head screw.
Check the adjustment and readjust if necessary.

Note
Do not adjust the drive belt too tight.

rev. 1.0 - 12/2009

5-91

075.1

Service Manual

Drive belt upper folder section

5 mm (0.2 inch)

The maximum movement of the drive belts at the indicated position is 5 mm (0.2 inch).
To adjust:
1
2
3
4

Slacken the hexagonal head screw (1) securing the belt tensioner (2).
Shift the belt tensioner to adjust the correct belt movement.
Hold the belt tensioner and retighten the hex. head screw.
Check the adjustment and readjust if necessary.

Note
Do not adjust the drive belt too tight.

5-92

rev. 1.0 - 12/2009

Service Manual

075.1

Paper guide

There must be a small gap between the fixed guide plate (3) and the fold roller (2). The fold
roller should just run free.
To adjust:
1
2

Slacken the two round head screws (1) to move the guide plate (3) further away from the
fold roller (2).
Tighten it to move it closer.

rev. 1.0 - 12/2009

5-93

075.1

Service Manual

Solenoids
Note
The adjustment procedure for all solenoids is described below. Only for the finger solenoids a
different procedure is necessary.
Whenever a solenoid is actuated the plunger is pulled into the solenoid coil. To make sure that
the pulling power of the solenoid coil on the plunger is maximal, the plunger should not touch
the bottom of the solenoid coil whenever the solenoid is actuated.

LH

RH
To set this requirement:
1
2
3
4
5

Slacken the two screws (3) securing the solenoid coil (4).
Push the plunger (2) together, with the linkage (1) attached to it, as far as it will go in the
direction towards the solenoid coil.
Hold the plunger in this position and then slide the solenoid coil towards the plunger until
the plunger bottoms the solenoid coil.
Move the solenoid coil back by approximately 1 mm (0.04 inch).
Retighten the two screws. Ensure the solenoid coil and the plunger are aligned in a straight
line.

5-94

rev. 1.0 - 12/2009

Service Manual

075.1

Finger solenoid

RH
1

To adjust the finger solenoid:


1
2
3
4

Slacken the two screws (2) securing the solenoid coil (1).
Push the plunger (3) down into the lowest position.
Move the solenoid coil (with the plunger in the lowest position) so that the middle fingers
(slide in) is adjusted approximately 2 mm (0.07 inch) (max.) above the insert table.
Retighten the two screws.

rev. 1.0 - 12/2009

5-95

075.1

Service Manual

Separation roller

Because the separation roller does not reverse, a 'flat' gradually wears on the roller surface. This
can be the cause of irregular feeding of the envelopes. Should this occur, carry out the following
adjustment:
1
2
3
4

Pull down lever (3).


Slacken screw (2) to rotate separation roller (1).
Rotate the separation roller about 60 degrees in the direction indicated, so that the unworn
portion of the separation roller faces the feed roller.
Fasten screw (2).
Close lever (3).

Note
After rotating the separation roller over 300 degrees it is necessary to replace it.

Note
If you have to turn the separation roller that far that screw (2) turns out of reach, move screw
(2) to the next hole in the separation roller.

5-96

rev. 1.0 - 12/2009

Service Manual

075.1

Friction brake

20 mm (0.79 inch)

The friction brake is correctly adjusted when the distance between the inner faces of the two
friction discs (3), i.e. the overall pressure spring length, is 20 mm (0.79 inch).
To adjust:
1
2
3

Remove the outer nut (1) securing the inner nut (2).
Turn the inner nut to adjust the correct distance.
Replace the outer nut and check the adjustment.

Note
An increased variation of the envelope stop position can be caused by excessive play in the
lower gear train. A slight reduction in the distance (increasing the pressure) may give the
required result.

rev. 1.0 - 12/2009

5-97

075.1

Service Manual

Flap scraper

RH

LH

The flap scraper (3) must be positioned so that its lower edge is aligned with the lower edge of
the envelope guide (1).
To adjust:
1
2
3

Slacken the two hexagonal head screws (2) securing the flap scraper (3) on both sides.
Move the flapscraper to adjust the correct position.
Retighten the two hexagonal head screws and check the adjustment.

Note
Depending on the envelope type and flap shape, a different setting may be necessary.

5-98

rev. 1.0 - 12/2009

Service Manual

5.3

Electrical description

5.3.1

075.1

PCBs

An overview of all PCBs:

Board number

Board name

2994502X

Display board

2994508D

Keyboard

2975540V (110 V) or
2975500D (220 V)

Motor relay board

2992003U (regular) or
2992001S (expanded) (optional)
2992002T (optional)

Connection board

2992000R (optional)

Communication board

2825900V or
2825942P

Main board
Pre-programmed main board

2994504Z

ID Tag

rev. 1.0 - 12/2009

Modem board

5-99

075.1

5.3.2

Service Manual

Display board

Wiring display board

LC display

Connector number

Cable number

J100

2989082B

J101

LC display CCFL

J103

LC display touchscreen

J104

LC display data

J210

2989082B

LC display
data

2994544R

LC display
y
CCFL

2994544R

5-100

rev. 1.0 - 12/2009

Service Manual

5.3.3

075.1

Keyboard

2994544R

Wiring keyboard

Connector number

Cable number

J100

2994544R

rev. 1.0 - 12/2009

5-101

075.1

5.3.4

Service Manual

Motor relay board

2
2994526X

2
2994526X

2
2994526X

Wiring motor relay board

main motor

Connector number

Cable number(s)

J1

2994526X

J2

2994526X
X

2994526X
X

not in
use

2994526X

Main motor
115 V: 2989407Q
230 V: 2989406P

J3

not in use

51

2994526X

52

2994526X

54

2994526X

55

2994526X

124

2994526X

5-102

rev. 1.0 - 12/2009

Service Manual

5.3.5

075.1

Connection board

a. Connection board, regular

2994532D
D

Wiring connection board (regular)

Connector number

Cable number

J101

2994532D

rev. 1.0 - 12/2009

5-103

075.1

Service Manual

b. Connection board, expanded (optional)

Wiring connection board (expanded)

2994532D

2994532D

Connector number

Cable number

J105

2994532D

J108

2994532D

Modem board
The modem board is attached to the expanded connection board.

5-104

rev. 1.0 - 12/2009

Service Manual

5.3.6

075.1

Communication board (optional)

rev. 1.0 - 12/2009

5-105

075.1

Service Manual

2
2994548V

2
2994532D

2
2994534F

2
2994532D

Wiring communication board

2994534F
F

Connector number

Cable number

J101

2994534F

J401

2994532D

J402

2994548V

J403

2994532D

J502

2994534F

5-106

rev. 1.0 - 12/2009

Service Manual

075.1

Testpoints and LEDs on the communication board

TP102

TP101

D201
D202
D203
D204
D205
D206

D302

TP207

TP208
TP202
TP206
TP207
TP105

TP203
TP201

TP106

rev. 1.0 - 12/2009

5-107

075.1

Service Manual

Testpoint

Name

Typical value

Function

TP101

GND

0V

Debug ground

TP102

GND

0V

Debug ground

TP105

+24V

24 V

Supply check

TP106

GND

0V

Electrical ground

TP201

SDO

Debug only

TP202

SDI

Debug only

TP203

SCLK

Debug only

TP205

PB 5

Debug only

TP206

PB 6

Debug only

TP207

PB 7

Debug only

TP208

PFO/CAL

Debug only

LED

Color

Name

Function

D201

Green

TestLED 0

No error heartbeat

D202

Green

TestLED 1

Modem activity

D203

Green

TestLED 2

Inserter communication activity (USB link)

D204

Green

TestLED 3

Franking interface (FIF) communication activity

D205

Green

TestLED 4

Service communication activity

D206

Green

TestLED 5

Debug LED

D302

Red

Flsh wrt

Flash write in progress indication

5-108

rev. 1.0 - 12/2009

Service Manual

5.3.7

075.1

Main board

rev. 1.0 - 12/2009

5-109

075.1

Service Manual

2
2989018K

Wiring main board

2825917N
N
2989032Z
Z

2994548V
V

2994534F
2994532D
D

2994530B
B

2
2989036D
2
2825916M

2825916M
M
2825915L
L
2994520R
R

2989022P
P
2989010B
B

5-110

2994536H

2994522T

2825914K

2
2989082B

rev. 1.0 - 12/2009

Service Manual

Connector number

Cable number

J100

2825916M

J101

2989036D

J102

2994526X

J500

2994520R

J501

2989020M

J502

2989022P

J600

2825916M

J602

2994522T

J603

2825914K

J604

2825915L

J650

2994536H

J700

2989010B

J701

2989018K

J800

2989028V

J801

2989024R

J802

2994530B

J901

2989032Z

J902

075.1

2989032Z
2825917N (in case of high capacity feeder)

J903

2989032Z

J904

2825916M

J1000

2989434T (reading head)

J1100

2994532D (without communication board)


2994534F (with communication board)

J1102

2994548V

J1120

2994534F

J1200

2989082B

rev. 1.0 - 12/2009

5-111

075.1

Service Manual

Testpoints and LEDs on the main board

T
TP103
T
TP105
TP901
TP900

T
TP102

TP903
TP902
TP904
TP906

T
TP100
T
TP101

TP800
D801

TP301

D303

TP300
D301
D300
D702
D701
TP205

TP1001
1

T
TP701

TP505
D500
TP600
TP500
TP502
TP501
TP503

5-112

rev. 1.0 - 12/2009

Service Manual

075.1

Testpoint

Name

Typical value

Function

TP100

+5V

5V

Supply check

TP101

-12V

-12 V

Supply check

TP102

+12V

12 V

Supply check

TP103

GND

0V

Electrical ground

TP105

+24V

24 V

Supply check

TP200

Window

5V

OMR window oscilloscope trigger

TP205

DBG5

Debug only

TP300

TST1

Debug only

TP301

TST2

Debug only

TP500

ENV

1.2 V

Envelope photocell

TP501

FLAP

1.2 V

Flap photocell

TP502

LOC

1.2 V

Loc photocell

TP503

EXIT

1.2 V

Exit

TP505

PDSC

5 V or 0 V

Main pulsedisc signal

TP600

CLOSER

1.2 V

Closer photocell

TP700

COLL

1.2 V

Collator photocell

TP701

FO

1.2 V

Folder photocell

TP800

PD COL

5 V or 0 V

Collator pulsedisc

TP900

FE-1

1.2 V

Feeder 1 photocell

TP901

FE-3

1.2 V

Feeder 3 photocell

TP902

DFC FE1

Depends on paper thickness

DFC out feeder 1

TP903

DFC FE3

Depends on paper thickness

DFC out feeder 3

TP904

FE-2

1.2 V

Feeder 2 photocell

TP906

DFC FE2

Depends on the paper thickness

DFC out feeder 2

TP1000

OMR OUT

Depends on the paper reflection and


marks

Analog OMR signal

TP1001

ReadHead

1.2 V

Readhead photocell

rev. 1.0 - 12/2009

5-113

075.1

Service Manual

LED

Color

Name

Function

D300

Green

TST1

No error heartbeat

D301

Red

TST2

Error heart beat

D303

Red

Flash write

Flash write in progress indication

D500

Green

PDSC

Main pulsedisc indication

D701

Green

FT1

Folding table 1 indication

D702

Green

FT2

Folding table 2 indication

D801

Green

PD COLL

Collator pulsedisc indication

Flex OMR
Note
Only use a dongle that is marked with the number 37, DS1977 (see following figure). This
dongle is not downwards compatible for other SI or SA products. Dongles marked with OC must
not be used on the 075.1.

number 37

DS1977

5-114

rev. 1.0 - 12/2009

Service Manual

5.3.8

075.1

ID-tag (2994504Z)

2994536H

Wiring ID-Tag

Connector number

Cable number

J100

2994536H

rev. 1.0 - 12/2009

5-115

075.1

Service Manual

5.4

Maintenance

5.4.1

Preventive maintenance

Average preventive service visits should take place at approximately 160.000 inserts (see
service menu, service counters). The table below shows the intervals.
Please note that there is a statistical relationship between the actual average monthly volume
and the service requirements of the machine. Significant larger average volumes might double
the yearly service requirements.
Maintenance

Number of cycles

Service visit

+/- 160.000

160k

+/- 330.000

160k

+/- 500.000

500k

+/- 660.000

160k

+/- 830.000

160k

+/- 1.000.000

500k

10

+/- 1.660.000

160k

11

+/- 1.800.000

160k

....

....
Note
It is recommended to service the machine at least twice a year.

Note
If the high capacity vertical stacker is installed (HCVS-1), refer to 10.5.3 Preventive
maintenance on page 10-54 for the maintenance schedule of the HCVS-1.

5-116

rev. 1.0 - 12/2009

Service Manual

5.4.2

075.1

160k Service visit

Estimated time to do the 160k service is 1 hour.


General

Check with the operator if there are any problems detected.

Visual inspection.
Vertical

Clean the photocells and check the function via the service menu.

Check the alignment of the document hoppers.


Document feeders

Replace the separation rollers (upper + lower) of the automatic separation feeder.

Check the separation function of the special feeder.

Replace all paper pullers of the feeders.


Inserter

Clean the sealing and closing area of the inserter.

Clean the photocells and check the function via the service menu.

Description

Page

Item

Part

Quantity

Upper separation roller

page 9-41

2951167G

Rubber paper puller

page 9-41

13

2040016R

Separation roller (lower)

page 9-42

59

2951168H

Upper separation roller

page 9-41

2951167G

2*

Rubber paper puller

page 9-41

13

2040016R

Separation roller (lower)

page 9-42

59

2951168H

2*

Feed roller kit 3 station expert

Feed roller kit 2 station expert

(*) Depending on the configuration

rev. 1.0 - 12/2009

5-117

075.1

5.4.3

Service Manual

500k Service visit

Estimated time to do the 500k service is 3 hours.


Additional parts to be replaced at each 500k.

Description

Page

Item

Qty.

Remarks

2040306T

Moistening cloth

Part

1 for spare

Feed roller 42 mm

page 9-13

13

2732731U

Jogger roller O-ring

page 9-13

2041876D

Finger

page 9-23

36

2964071Y

Transportation roller 30 mm

page 9-27

27

2964364D

At insert

Brush

page 9-29

19

2720005N

3 for spare

Collating belt set (3 pcs.)

page 9-55

30

2952007G

Pressure roller inc. O-ring (assy)

page 9-55

21

2952011L

Transportation table (assy)

page 9-23

47

2964567Q

Transportation roller 38mm

page 9-29

28

2042977A

General

Check with the operator if there are any problems detected.

Visual inspection.
Vertical

Clean the rollers of the vertical track.

Clean the collating belts and check the tension of the belts.

Check the tension of the driving belts.

Slightly lubricate the bearings.


Document feeders

Clean the rollers per feeder.

Clean the freewheel clutch in Pulley 28T- see item 14 on page 9-41 in Section 9.17
Document feeder unit (automatic) - and lubricate it lightly.

Clean the freewheel clutch in Gear 64T assy - see item 38 in Section 9.18 Document feeder
unit - special 1/2 - and lubricate it lightly.

Clean the thickness detector and check it via the service menu.
Envelope track

Check the separation roller, turn it a little inwards when a flat side is present.

Replace the feed roller - see Rollers on page 5-56.

Replace the O-rings of the jogger rollers.

Clean the rollers of the envelope track.

Check if the rollers are still clicked correctly.

5-118

rev. 1.0 - 12/2009

Service Manual

075.1

Inserting area + loc + exit

Replace the transportation rollers 30mm - see item 26 in Section 9.10 Insert and eject
mechanism - which are placed above the lower insert rollers.

Clean other rollers in the loc.

Clean braking plate assy. and cover loc - see items 9 and 21 in Section 9.12 Envelope
closing mechanism.

Replace the brushes and the moistening cloth.

Clean the upper and lower sealing rollers.

Clean the lower insert rollers.

Replace all the fingers.


Drive mechanism

Check the chain tension, lubricate lightly if necessary.

Check the belt tension.

Clean the pulse disc and the accompanying sensor.

Lightly lubricate the bearings.

rev. 1.0 - 12/2009

5-119

075.1

5-120

Service Manual

rev. 1.0 - 12/2009

Service Manual
6

075.1

Fault finding

There are three kinds of errors:

Hardware related errors that make further paper processing impossible. The error screen
displays a call service pictogram.

Hardware related errors at which further paper processing is still possible.

Operational errors, in most cases paper flow errors.


An error may result into:

A soft stop. An error situation forces the machine to stop. After solving the problem the
process can be resumed. The machine part with the problem is directly stopped, but in other
machine parts envelopes and documents are transported to the next stop position.

A hard stop. An error forces the machine to stop and the process cannot simply resumed
after solving the error. The machine must be switched off. An example of a hard stop is the
opening of a microswitch-guarded cover. All main motor-driven moving parts of both the
system are abruptly stopped. The process timing (based on pulses delivered by slotted
photocells) is completely disrupted.
If an error occurs in one of the parts of the system, an error screen
is displayed. The display shows a screen showing the following
information:

An indication of the area in which the error occurred.

An error description.

A suggested solution behind the pointing hand.


Press the i button to view more information about the occurred
error and about the possible actions to avoid the error from reoccurring. After solving the problem, press the reset button to
reset the error (the error screen will disappear).
Priority
Usually the error that appears first, is displayed first.
There are however some exceptions:

A hard stop error prevails over a soft stop error.

A soft stop error prevails over a divert stop error.


If a feeder hopper is empty the machine continues the process until the last complete set is
handled.
As far as simultaneous errors in various system parts are concerned the priorities are: inserter,
folder, vertical transport, feeder.

6.1

Resolve problems remotely

For remotely diagnosing customer problems, check the following with the customer:

The machine type and serial number:


1
Look on the sticker (on the internal frame)
2
Open the front cover
3
Read the machine type and serial number

The customer's Failure description. See Section 10.3.1 Failure symptoms.

The error message coming with the failure. This can be checked by the supervisor:
1
Enter the supervisor menu
2
Select system info
3
Read the last error
4
Check the counter since last service visit
5
Check the software versions installed

rev. 1.0 - 12/2009

6-1

075.1

Service Manual

In case of a system with connectivity to online services, ask the supervisor to make a
manual connection.
Select a follow up process:
1
Guide the supervisor through a remote resolution process (with or without online
services). A trained remote service engineer needs to be consulted.
2
When sufficient cycles have been done since last service visit, schedule a preventive
maintenance visit. Schedule enough time for both the engineer and the customer.
3
When there is no clue about the exact cause of the failure, schedule a corrective
maintenance resolution process. A trained field engineer needs to be consulted.

6.2

Troubleshooting Online Services

If it is not possible to connect the machine to the server, use this troubleshooting table to find
the cause.
No sound after pressing
"Connect"

Check if the preparations described in 7.7.1 Preparations on page 7-1 are


met.
Check modem volume in the configuration menu.
Check if the telephone cable is connected.
Check the wall socket, ask the customer if the telephone line is patched.
Check if the dial tone is set to on in the configuration setting menu. For some
PABX telephone systems switch dial tone off.
Main menu -> Supervisor menu (pin 2546) -> Online Services ->
Configuration

Sound after pressing


"Connect"

Check if preparations described in 7.7.1 Preparations on page 7-1 are met.


Check the telephone number, the telephone number can be found on Neoweb.
Check in the service menu the IP address:

192.168.20.217 (Europe)
172.16.100.10 (USA)

Main menu -> Supervisor menu (pin 4351) -> Online Services -> Server port
Check in the service menu the Port number:

5001 (Europe)
1003 (USA)

Main menu -> Supervisor menu (pin 4351) -> Online Services -> Server port
Check in the service menu Suffix: Osiris.FR.FT
Main menu -> Supervisor menu (pin 4351) -> Online Services -> Server port
System stops automatic
call

6.3

The system stops the automatic call if the call fails three times. Execute a
manual call. This also reschedules the automatic calls.

Error handling inserter

After pressing the i button in an error message screen, the display can show an error code.

6-2

rev. 1.0 - 12/2009

Service Manual

075.1

The error format of inserter errors is as follows: INS-XXX-YYY. The FRM messages are explained
in 6.4 Error handling franking machine on page 6-25. XXX is an abbreviation that indicates a
specific machine part. The following machine areas/prefixes apply:
XXX

Explanation

Reference

BAT

Battery

6.3.1 Battery errors (BAT) on page 6-4

CL

MPPC errors

6.3.2 MPPC errors (CL) on page 6-4

CLS

Closer

6.3.3 Closer errors (CLS) on page 6-4

COM

Communication

6.3.4 Communication errors (COM) on page 6-5

CT

Collator

6.3.5 Collator errors (CT) on page 6-6

DC

DFC

6.3.6 DFC errors (DC) on page 6-6

DF

Document Feeder

6.3.7 Document feeder errors (DF) on page 6-7

DG

Dongle

6.3.8 Dongle errors (DG) on page 6-7

EH

Envelope Hopper

6.3.9 Envelope hopper errors (EH) on page 6-8

EOP

Envelope Open

6.3.10 Envelope open errors (EOP) on page 6-8

FOL

Folder

6.3.11 Folder errors (FOL) on page 6-9

INS

Insert

6.3.12 Insert errors (INS) on page 6-9

JOB

Job

6.3.13 Job errors (JOB) on page 6-10

LD

Level Detector

6.3.14 Level detector errors (LD) on page 6-11

LIC

License

6.3.15 License errors (LIC) on page 6-11

Motor

6.3.16 Motor errors (M) on page 6-12

MOD

Modem

6.3.17 Modem errors (MOD) on page 6-12

OLS

Online service

6.3.18 Online service errors (OLS) on page 6-14

OR

Reading head

6.3.19 Reading head errors (OR) on page 6-15

Photocell

6.3.20 Photocell errors (Pxx) on page 6-15

PB

PCB

6.3.21 PCB errors (PBx) on page 6-18

PD

Pulse Disc

6.3.22 Pulse disc errors (PD) on page 6-18

PRC

Production Control

6.3.23 Production control errors (PRC) on page 6-19

RE

Reading

6.3.24 Reading errors (RE) on page 6-19

SM

State Machine

6.3.25 Machine state errors (SM) on page 6-22

STK

Stacker

6.3.26 Stacker errors (STK) on page 6-22

SW

Switches

6.3.27 Switches errors (SW) on page 6-23

SYS

System

6.3.28 System errors (SYS) on page 6-23

TR

Transport

6.3.29 Transport errors (TR) on page 6-24

rev. 1.0 - 12/2009

6-3

075.1

6.3.1

Service Manual

Battery errors (BAT)

Error

Message

Cause

INS-BAT400

Technical failure

Power dip on communication At IN startup and configuration check


board. OLS error.
(only if OLS is switched on in service
menu).

6.3.2

Information

MPPC errors (CL)

Error

Message

Cause

Information

INS-CL1301

No ID

Scanner did not read an ID.

Check scanning position on envelopes.

INS-CL1302

Invalid ID

The ID of the last envelope is Remove envelope and check why


unknown to BSPI.
envelope ID number is unknown to
integrity control.

INS-CL1303

Duplicate ID

The ID of the last envelope


was already processed
before by BSPI.

INS-CL1304

ID's out of sequence The ID of the last envelope is Remove envelope and check envelope
out of sequence with the
sequence or restart the integrity
previous ones.
control.

INS-CL1900

PC saving problem

BSPI cannot save the ID of


the last envelope in its
database.

Check BSPI application for details.

INS-CL1901

PC problem

The BSPI application


encounters a problem.

Check BSPI application for details.

Information

6.3.3

Remove envelope and check why


envelope has a previously used ID.

Closer errors (CLS)

Error

Message

Cause

INS-CLS110

Envelope closer
failure

Envelope path not cleared


This error is generated if the closer cell
after previous jam, envelope is covered at the moment an envelope/
closing sensor readjustment document should leave the insert area.
needed, dirty sealing track,
insert failures.

INS-CLS111

Envelope closure
failure

Envelope closing path not


cleared after previous jam,
slippage, dirty sealing track,
insert failures, skewing.

INS-CLS290

Unexpected
document at exit

Document which should have Reset to continue.


been removed wasn't
removed.

6-4

This error is generated if the flap closer


sensor is covered too long. Longer than
the time that meets a document
transport of 550 flanks (approx. 275
mm).

rev. 1.0 - 12/2009

Service Manual

6.3.4

075.1

Communication errors (COM)

Error

Message

Cause

Information

INS-COM900

Technical failure

INS-COM901

Technical failure

SCS/I2C protocol problem,


cables, connectors, PCBs.

System error. This error is generated if


something is wrong with the SCS/I2C.

INS-COM902

Technical failure

SCS/I2C protocol problem,


cables, connectors, PCBs.

System error. This error is generated if


something is wrong with the SCS/I2C.

INS-COM903

Technical failure

SCS/I2C protocol problem,


cables, connectors, PCBs.

System error. This error is generated if


something is wrong with the SCS/I2C.

INS-COM904

Technical failure

SCS/I2C protocol problem,


cables, connectors, PCBs.

System error. This error is generated if


something is wrong with the SCS/I2C.

INS-COM905

Technical failure

SCS/I2C protocol problem,


cables, connectors, PCBs.

System error. This error is generated if


something is wrong with the SCS/I2C.

INS-COM906

Technical failure

SCS/I2C protocol problem,


cables, connectors, PCBs.

System error. This error is generated if


something is wrong with the SCS/I2C.

INS-COM907

Technical failure

SCS/I2C protocol problem,


cables, connectors, PCBs.

System error. This error is generated if


something is wrong with the SCS/I2C.

INS-COM908

Communication
failure

Communication failure.

Call service.

INS-COM910

Technical failure

ISIS link down between main Communication lost between inserter


board and communication
and communication board.
board.

INS-COM911

Technical failure

Communication lost between Reset to continue.


inserter and connection
board.

INS-COM930

No communication

Communication error
Check cables and connectors.
between inserter scanner or
BSPI PC.

rev. 1.0 - 12/2009

6-5

075.1

6.3.5

Service Manual

Collator errors (CT)

Error

Message

INS-CT1100

Document transport Document type, document


failure
path blockage, photocells
dusty, photocells defect.

INS-CT1110

Collator stop error

INS-CT1120

Document transport Document set missing from


failure
collator, photocells
readjustments needed,
photocells defect.

This error is generated if no documents


arrive at the folder entry cell. Possible
causes: paper crash or the operator
pressed the stop button, removed the
set from the collator and pressed start.

INS-CT1290

Unexpected
Collator not cleared after
document at collator previous emergency stop.

During initialization of the collator a set


is seen under the folder entry cell. The
collator is initialized after fatal feeder
errors, after collator errors and after a
change of job.

INS-CT1400

Collator stop
reference detection
failed

Zero position sensor failure,


rack broke or collator stop
motor failure.

During initialization of paper stop


detection, the sensor for detecting zero
position could not detect the zero
position.

INS-CT1401

Collator stop
detection failed

Stop position sensor failure,


rack broke or collator stop
motor failure.

During initialization of paper stop


detection the sensor for detecting paper
stop position could not detect the zero
position.

6.3.6

Cause

Information
This error is generated if the collator
entry cell is covered too long. Possible
causes: too stiff material, collator
blocked.

Incorrect collator stop


This error is generated if it takes too
position, mechanical failure. long before a set arrives at the folder
entry sensor. Is only checked at job
start.

DFC errors (DC)

Error

Message

Cause

Information

INS-DC1401

Technical failure

DFC defect, cables defect.

This error is generated in a job where


the DFC is turned on while it is defect.
This error returns after each change of
job.

INS-DC1402

Feeding failure

Document separation failing, This error is generated when the DFC


DFC defect, cables defect.
can not see the difference between
paper being present or not present. This
can be caused by a continuous flow of
paper (no space in between sheets) or
by a defect in the DFC. After reset, a
new reference value is taken. When still
no difference is measured, error INSDC1-402 shows. There is a defect in the
DFC.

INS-DC1402

DFC failure

DFC defect, cables defect.

6-6

This error is generated if the DFC can


not be adjusted.

rev. 1.0 - 12/2009

Service Manual

6.3.7

075.1

Document feeder errors (DF)

Error

Message

Cause

Information

INS-DF1000

Empty feeder

Empty feeders, wrong


document type, document
width setting, manual
document separation
adjustment.

This error is generated if a feeder is


empty. This can be put right by refilling
the feeder and pressing Reset. This is no
fatal error, after restarting the job, the
set will be finished. In order to do a
restart after this error, press the start
button.

INS-DF1110

Document stoppage Blocked document path,


document separation
adjustment (manual
separation only), document
type, document job settings,
photocells dusty.

This error is generated if a feeder


processes a document and it is found
that the document is at least 50%
longer than the document size that was
set up for that feeder in that particular
job. This is a fatal error.

INS-DF1200

Document too short Incorrect document type,


document job settings,
photocell readjustment
needed.

This error is generated if a feeder


processes a document with a length that
is more than 45 mm shorter than the
document size that was set up for that
feeder in that particular job. This is a
fatal error.

INS-DF1201

Document too long

Document separation
adjustment (manual
separation only, document
type, document job settings,
photocells dusty.

This error is generated if a feeder


processes a document that is more than
20% longer than the document size that
was set up for that feeder in that
particular job. This is a fatal error.

INS-DF1300

Feeding failure

Incorrect thickness
This error is generated if the sheet on
reference, irregular
which the DFC is adjusted was a double
document types, DFC defect sheet. This error can only be generated
or loose.
with the first sheet that a feeder
processes after adjustment (when this
sheet is thinner than the one that was
used for the adjustment). This is a fatal
error.

INS-DF1301

Document too thick

Document type, document


separation adjustment
(manual separation only),
separation rollers worn out.

This error is generated if a feeder


inserts a double page. This is a fatal
error.

6.3.8

Dongle errors (DG)

Error

Message

Cause

Information

INS-DG1400

Technical failure

Incorrect dongle installed,


dongle contents cannot be
read.

OMR error. This error is generated if the


dongle checksum is incorrect or if the
serial number check is incorrect.

rev. 1.0 - 12/2009

6-7

075.1

6.3.9

Service Manual

Envelope hopper errors (EH)

Error

Message

Cause

Information

INS-EH1000

Empty envelope
hopper

Empty hopper, wrong


envelope type, envelope
width setting, envelope
separation adjustment,
envelope feeding angle.

This error is generated if it takes longer


than 15 seconds to detect an envelope
at the envelope track sensor after the
envelope track was started.

INS-EH1200

Envelope too short

Incorrect envelope type,


envelope job settings,
photocell readjustment
needed.

This error is generated if the envelope is


measured shorter than 75 mm. Also
when envelope height is measured
shorter than adjusted envelope height
minus 20 mm.

INS-EH1201

Envelope too long

Envelope separation
adjustment, envelope type,
envelope quality, envelope
job settings, photocells
dusty.

This error is generated if a closed


envelope is measured higher than 182
mm (162 mm + 20 mm tolerance) or if
the envelope is measured higher than
the adjusted envelope height plus 20
mm.

6.3.10 Envelope open errors (EOP)


Error

Message

Cause

INS-EOP300

Envelope not open

Envelope exit path, slippage, This error is generated if the envelope


envelope type, inserting
does not arrive within 400 mm (800
failure, flap closer sensor.
flanks) at the exit cell, after detecting
the envelope by the closer switch.

6-8

Information

rev. 1.0 - 12/2009

Service Manual

075.1

6.3.11 Folder errors (FOL)


Error

Message

Cause

Information

INS-FOL100

Folder entry
blockage

Document feeding,
document separation,
document path not cleared
after previous stoppage,
skewing of set, slippage.

This error is generated if the folder


entry cell is covered longer than 500
pulses (about 475 mm). Caused by
incorrect folder transport, or the
document is blocking in collator.

INS-FOL111

Folding failure

Document set thickness,


mechanical defect in first
fold table, folding sensors
defect.

This error is generated if 500 ms after


powering the clutch of the first fold table
no flank is detected on the curve disc
sensor of the first fold table. Possible
causes: fold table blocking by a not
foldable document (stiff material),
mechanical defect on fold table, clutch
or sensor.

INS-FOL112

Folding failure

Document set thickness,


mechanical defect in first
fold table, folding sensors
defect.

This error is generated if 500 ms after


powering the clutch of the second fold
table no flank is detected on the curve
disc sensor of the second fold table.
Possible causes: fold table blocking by a
not foldable document (stiff material),
mechanical defect on fold table, clutch
or sensor.

INS-FOL120

Document stoppage Set not removed after job


change.

This error is generated when paper is


left in the folder after a job change.

6.3.12 Insert errors (INS)


Error

Message

Cause

Information

INS-INS100

Document inserting
failure

Insert fingers, envelope stop


position, envelope job
settings, document skewing,
document, slippage,
document feeding, envelop
feeding.

This error is generated if the insert cell


is covered too long during inserting. Too
long means longer than 400 mm (800
flanks).

INS-INS101

Envelope stoppage

Blocked envelope path,


This error is generated if the flap sensor
envelope separation
is covered more than 690 flanks
adjustment, envelope type, (approx. 345 mm).
envelope job settings, dusty
photocells, slippage.

INS-INS102

Document stoppage Blocked document path,


slippage.

rev. 1.0 - 12/2009

This error is generated if the called


document does not arrive at the insert
cell.

6-9

075.1

Service Manual

Error

Message

Cause

Information

INS-INS103

Insert area blocked

Blocked document or
This error is generated if a document
envelope path after previous covers the insert cell at the moment the
stoppage.
system is started.

INS-INS290

Unexpected
document

Document path not correctly This error is generated if a document


cleared after previous error, arrives at the insert area at a not
slippage, inserting failures.
expected moment.

INS-INS290

Unexpected
document

Document path not correctly This error is generated if the insert cell
cleared after previous error, is covered at the moment a document is
slippage, inserting failures.
called.

INS-INS303

Document length
failure

Insert fingers, envelope stop


position, document job
settings, document skewing,
document slippage,
document feeding.

This error is generated if on two inserts


directly after each other a length
difference is measured of more than 42
mm (84 flanks). This means irregular
inserting (slip on insert rollers?).

6.3.13 Job errors (JOB)


Error

Message

Cause

Information

INS-JOB000

Empty feeders

Empty feeders, wrong


document type, document
width setting, manual
document separation
adjustment.

This error is generated if all feeders are


empty during the loadn Go scanning
session.

INS-JOB200

MaxiFeederTM
failure

Incorrect job settings for


maxiFeeder.

This error is generated if an MF is


plugged in and a job is started that does
not comply with the specifications of the
MF-3. This can occur when the lowest
feeder is a complete station, and the
document length is adjusted to >156
mm and/or to multifeed.

INS-JOB201

Unauthorized job

Incorrect document job


settings, dongle reading
failure.

This error is generated if a 2 station


machine is reconstructed to a 1.5
station machine (dongle removed) and
a job is started that does not comply
with the specifications for a half station.
This is the case when the document
length for that half station is adjusted to
>156 mm and/or to multifeed.

INS-JOB202

MaxiFeederTM
failure

Refer to INS-JOB-200.

Refer to INS-JOB-200.

INS-JOB300

not possible

Not supported documents


and envelope type detected
for loadn Go.

This error is generated when due to


folder limitations the fold can not be
made that was calculated based on
measured document lengths and
envelope height.

6-10

rev. 1.0 - 12/2009

Service Manual

075.1

6.3.14 Level detector errors (LD)


Error

Message

Cause

Information

INS-LD1200

Sealing risk

Low level sealing liquid.


The sealing liquid level is between 1 and
Envelopes may not be closed 6 mm.
properly.

INS-LD1400

Sealing reservoir is
not detected

Insert reservoir.

6.3.15 License errors (LIC)


Error

Message

Cause

INS-LIC200

Invalid license key


entered

Invalid licence key, or licence This error is generated if the entered


key for other machine.
license key (via supervisor menu) could
not be recognized or translated into a
valid option by the system. This error
can also be generated when the factory
license key could not be recognized or
translated to a set of valid options.

INS-LIC400

Update options
failed

ID/Option memory defect.

This error is generated if the addition of


an option into the option memory fails,
because the encrypted contents of the
ID tag does not match what is expected.

INS-LIC401

Option memory
failure

Option memory defect or


general hardware defect.

This error is generated if the ID tag is


not seen during power up. Reason can
be that option wiring is not connected or
that there is something wrong with the
hardware.

INS-LIC402

Option memory
failure

ID memory empty, wiring


defect, ID/Option memory
defect.

This error is generated if the ID tag


could not be read, both the system ID
or the options. Also when the system
code is not valid (depends on the
alphabet characters in the system ID).
This error will occur every time the
system is started, and the system can
function without the options.

INS-LIC403

Invalid data in
option memory/ID
tag

The option data in the tag is


not valid. It has a wrong
checksum. The most likely
cause of this failure is either
an error in the hardware or
the connection of a wrong/
uninitialized tag to a
machine.

This error is generated if the entered


license key (via supervisor menu) could
not be recognized or translated into a
valid option by the machine.

rev. 1.0 - 12/2009

Information

6-11

075.1

Service Manual

6.3.16 Motor errors (M)


Error

Message

Cause

Information

INS-M03400

Technical failure

Blockage of collator, collator This error is generated if the DC motor


pulse disc defect, collator
of the collator is not running while it is
motor defect
supposed to. The error is shown when
there are no pulses detected for 100
ms. This can be caused by:
- a mechanical blockade as a result of
which the motor is running roughly
- not properly functioning of the pulse
disk of the collator
- a defect to the electric drive of the
collator motor
- a defect motor

6.3.17 Modem errors (MOD)


Error

Message

Cause

INS-MOD200

OLS dialling
interrupted by user

The user/supervisor pressed OLS message: at the initiation of a new


the disconnect button while OLS connection and the drilling is
dialing out.
interrupted by user.

INS-MOD300

No dial tone

The modem failed to detect a


dial signal. Could also
happen if the phone line is
not connected.

OLS message: at Osiris connection set


up.
Check the phone line (e.g. by
connecting a normal analogue phone
and listening to the receiver. If there is a
Dalton, try disabling the dial tone detect
in the OLS configuration screen on the
device).

INS-MOD301

OLS dialling
interrupted
unexpectedly

INS-MOD302

OLS line busy

The phone number being


dialed is busy.

OLS message: at the initiation of a new


OLS connection and there is no
incoming phone line available at the
server or there is congestion on the
public phone network. Try again later

INS-MOD303

No carrier

The modem failed to


OLS message: at the initiation of a new
negotiate with the modem of OLS connection. This could have
the server.
multiple reasons. E.g. the quality of the
line is bad or the negotiation with the
modem of the server failed. Try again
later. If it continues to fail repeatedly
verify line signal quality for example by
connecting an analogue phone to the
line and listen to the dial tone, try to
make an external call.

6-12

Information

rev. 1.0 - 12/2009

Service Manual

075.1

Error

Message

Cause

Information

INS-MOD400

Technical failure

Modem not ready or serial


port initialization of modem
failed.

OLS error at IN startup and


configuration check (only when OLS is
switched on in service menu).

INS-MOD401

No analogue phone
detected

There is no analogue phone OLS message: at Osiris connection set


line connected to the
up.
machine or the line is faulty. Check the phone line.

INS-MOD580

Technical failure

No modem available/
detected, modem defect,
modem not plugged in, cable
defect, no connector board,
connector board defect.

rev. 1.0 - 12/2009

OLS error. At IN startup and


configuration check and modem is
expected because of service settings or
licence.

6-13

075.1

Service Manual

6.3.18 Online service errors (OLS)


Error

Message

Cause

Information

INS-OLS000

New online service


messages

New OLS message on


communication board.

OLS message. At start up of system


when OLS is enabled and new messages
are available in OLS menu.

INS-OLS300

OLS server not


responding

INS-OLS301

OLS server not


ready

INS-OLS302

OLS connection
refused by server

At setting up an OLS
connection the
authentication process of the
system failed because
system is not allowed to
connect.

OLS message: the IP settings are not


correct.
Check IP number and port. Also it could
be possible that the device is not
allowed to authenticating.

INS-OLS303

Protocol error

The connection to the server


succeeded but the server
doesn't allow this device to
communicate with the
server.

OLS message: the device is not known


by the server. Check on the OLS server
if this device serial number is known by
the server.

INS-OLS304

OLS connecting to
server failed (timeout answer)

INS-OLS305

Low infrastructure
quality

INS-OLS306

Automatic stats
upload failed

The upload of statistics is


interrupted.

Ask OLS server administrator to


investigate.

INS-OLS307

Configuration
upload/download
failed

The upload of the


configuration information is
interrupted.

Ask OLS server administrator to


investigate.

INS-OLS308

Automatic software
download failed

A software download is
interrupted.

Ask OLS server administrator to


investigate.

INS-OLS309

Automatic job
download failed

A job download is
interrupted.

Ask OLS server administrator to


investigate.

INS-OLS310

Automatic feature
download failed

A feature download is
interrupted.

Ask OLS server administrator to


investigate.

INS-OLS311

Automatic flex code


download failed

A flex OMR download is


interrupted.

Ask OLS server administrator to


investigate.

INS-OLS312

Auto connection
failure

Automatic connection failed.


Statistic buffer overflow
>95%, batch data might be
lost.

OLS error. During operations, when stop


or clear is pressed and the system is
stopped, and allocated memory is
getting full. Only when OLS is on en
options statistics is enabled.

6-14

rev. 1.0 - 12/2009

Service Manual

075.1

6.3.19 Reading head errors (OR)


Error

Message

Cause

Information

INS-OR1400

Technical failure

Reading head dirty, LED


defect, photocell defect,
cables defect.

OMR error. This error is generated if the


LED in the reading head is defect.

6.3.20 Photocell errors (Pxx)


The coding of the photocells is as follows:
Photocell code

Reference photocell

P01

Envelope track sensor

P02

Envelope flap sensor

P03

Insert table sensor

P04

Exit sensor

P05

Closer sensor

P06

Folder entry sensor

P07

Vertical track sensor

P08

Collator entry sensor

P09

Feeder sensor

P10

Feeder sensor

P11

Feeder sensor

The error list below covers all photocell errors.


Note
The error numbers can be different for some photocells.

rev. 1.0 - 12/2009

6-15

075.1

Service Manual

Error

Message

Cause

Information

INS-Pxx300

Photocell dusty

Low voltage received by the


photocell (dusty).

Dust error.
This error is generated if the DAC
current becomes too high during
operation. You are warned if the DAC
current increases and the sensor power
decreases (< 0,8 V). This error is
generated each 25 docs.
After pressing the reset button, the
following warning message appears:
1 Remove paper at sensor position
2 Clean sensor with bellow or brush
3 Press OK to reset sensor
SK4: The involved photocell values are
reset.
Go back to the main menu.

INS-Pxx300

Sensor error

Too much voltage received


by photocell. Current cannot
be correctly adjusted (too
low)

Overexposure receiver error.


This error is generated if the involved
photocell is too sensitive: during
adjustment the LED current becomes
too low (adjustment after 25 sheets).
Lower limit is 5/256 x100%.
After pressing the reset button, the
following warning message appears:
1 Remove paper at sensor position
2 Clean sensor with bellow or brush
3 Press OK to reset sensor
SK4: The involved photocell values are
reset.
Go back to the main menu.

INS-Pxx302

Technical failure

LED current adjusted too


low. Photocell sensor adjust
error

Photocell adjust error.


This error is generated if the involved
photocell can not be adjusted correctly.
The DAC current is too low (<5/256
X100%). Only when the system is
started the first time or when the
system is adjusted again after a dusty
error.
After a reset, the error message
disappears. If the particular photocell is
not needed for the selected job, the job
can still be carried out. If the photocell
is needed or if a new job is selected, the
error appears again as soon as the start
button is pressed or a test run is
performed.

6-16

rev. 1.0 - 12/2009

Service Manual

075.1

Error

Message

Cause

Information

INS-Pxx302

Sensor error

Voltage received by the


photocell is too high due to
dust fall off

Dust error. This error is generated if the


voltage in the involved photocell
receiver suddenly increases significantly
(e.g. by dust that falls off). Danger
arises that the voltage in de receiver (>
1,5 V) stays too high when paper is
present. After pressing the reset button,
the following warning message appears:
1 Remove paper at sensor position
2 Clean sensor with bellow or brush
3 Press OK to reset sensor
SK4: The involved photocell values are
reset. Go back to the main menu.

INS-Pxx303

Technical failure

Sensor adjust error. Led


current cannot be adjusted
to have photocell voltage
between 0,8 and 1,3 V.
Dusty, incorrect positioning,
incorrectly assembled.

Photocell adjust error.


This error is generated if the involved
photocell can not be adjusted correctly.
Transmitter power is too high and
receiver power is smaller than 0,8 V
(e.g. contamination, not correctly
connected, not correctly aligned). Only
when the system is started the first time
or when the system is adjusted again
after a dusty error.
After a reset, the error message
disappears. If the particular photocell is
not needed for the selected job, the job
can still be carried out. If the photocell
is needed or if a new job is selected, the
error appears again as soon as the start
button is pressed or a test run is
performed.

INS-Pxx401

Technical failure

Sensor defective. Photocell, Power up photocell detection error.


cables or connectors defect. This error is generated if no LED current
is detected in the involved photocell
(LED incorrect or not connected) during
powering up the system.
After a reset, the error message
disappears. If the particular photocell is
not needed for the selected job, the job
can still be carried out. If the photocell
is needed or if a new job is selected, the
error appears again as soon as the start
button is pressed or a test run is
performed.

rev. 1.0 - 12/2009

6-17

075.1

Service Manual

6.3.21 PCB errors (PBx)


Error

Message

Cause

Information

INS-PB1300

Technical failure

FRAM chip contains old data System error. This error is generated
structure.
during starting up of the machine.

INS-PB1301

Technical failure

FRAM chip contains corrupt


data.

System error. This error is generated


during reading of a data block.

INS-PB1402

Technical failure

FRAM chip is not available.

System error. This error is generated


during starting up or operation of the
machine.

INS-PB1403

Technical failure

FRAM chip is not formatted.

System error. This error is generated if


the machine is started up (at least) the
first time.

INS-PB1404

Technical failure

Communication failure

INS-PB2301

Technical failure

FRAM not formatted.

During start up, and OLS/FIF is enabled.

INS-PB2301

Technical failure

FRAM contains old data


structure.

During start up, and OLS/FIF is enabled

INS-PB2301

Technical failure

FRAM contains corrupt data. When reading data block

INS-PB2400

Technical failure

Clock update received from


server failed.

During run, system should continue.

INS-PB2406

Technical failure

Internal cables defect or


communication/connection
board defect.

INF error. At IN startup and


configuration check (only when INF
options are enabled). Also when INF job
is started or INF job is edited and no
communication is possible.

INS-PB2407

Technical failure

FRAM chip not available on


communication board.

During start up, and OLS/FIF is enabled.

INS-PB2408

Technical failure

PCB communication board


failure.

During start up of the system (and OLS/


FIF is enabled).

6.3.22 Pulse disc errors (PD)


Error

Message

Cause

INS-PD1400

Technical failure

Main motor defect, pulse disc System error. This error is generated if
defect, cables defect.
the pulse disk of the main power does
not generate enough pulses or if the
width of the pulses is irregular. The
motor is too heavily loaded or the pulse
disk is defect. For the boundaries, refer
to the pulse disk test in the service
menu.

6-18

Information

rev. 1.0 - 12/2009

Service Manual

075.1

6.3.23 Production control errors (PRC)


Error

Message

Cause

Information

INS-PRC000

Automatic clear of
system

Special clear for documents

Remove documents from collator.

INS-PRC290

Unexpected
documents in
system

System not cleared after job This error is generated if documents are
change
still in the system after a change of
jobs. This can be prevented by ending a
job with emptying the system, before
changing jobs.

6.3.24 Reading errors (RE)


Error

Message

Cause

Information

INS-RE1000

Reading stop

Stop mark read.

OMR error. Remove the set and press


Reset. A complete set is on the collator
and must be handled manually.

INS-RE1003

Suspected set

Incomplete sets collected


after reading error.

OMR error. This error is generated after


an earlier appeared reading error. The
paper run command insert is read.
The earlier appeared reading error
probably occurred halfway a set,
because of which that set and the next
one are incomplete.

INS-RE1003

Final set part

Incorrect marks read,


reading job settings.

OMR error. This error is generated if the


remains of the set (until the insert sign)
are collated after removing an
incomplete set and pressing Reset and
Start for error INS-RE1-312. If again
the maximum amount of sheets in a set
is exceeded, error INS-RE1-312 is
generated again.

INS-RE1300

Wrong reading
window position

Incorrect reading job


settings.

OMR error. This error is generated when


the reading window is behind the end of
the paper.

INS-RE1302

Reading error

Less marks read than


expected.

OMR error. This error is generated if less


reading code marks are seen, than
possible with the chosen reading code.
The set can - but does not need to - be
taken out of the collator. After a restart,
the rest of the set is finished, after
which error INS-RE1-003 shows.

INS-RE1303

Reading error

More than 1 basic command OMR error. This error is generated if


(accumulate/ insert/ divert/ more paper running assignments are
stop mark) read.
readable in the bar code. The set can but does not need to - be taken out of
the collator. After a restart, the rest of
the set is finished, after which error
INS-RE1-003 shows.

rev. 1.0 - 12/2009

6-19

075.1

Service Manual

Error

Message

Cause

Information

INS-RE1304

Reading error

No basic command
(accumulate/ insert/ divert/
stop/ start/ safety mark)
read.

OMR error. This error is generated if no


barcode line that indicates the paper run
(accumulate/ insert/ divert/ stop mark)
is found. Start and safety mark
included. The set can - but does not
need to - be taken out of the collator.
After a restart, the rest of the set is
finished, after which error INS-RE1-003
shows.

INS-RE1305

Reading error

Matching varies within the


set.

OMR error. This error is generated if one


sheet within a set has another match
number (only with Flex code). The set
can - but does not need to - be taken
out of the collator. After a restart, the
rest of the set is finished, after which
error INS-RE1-003 shows.

INS-RE1306

Reading error

Sequence number of
document does not match
with previous document.

OMR error. This error is generated if the


order, as guarded by the sequence
numbering of the documents, is no
longer correct. The set can - but does
not need to - be taken out of the
collator. After a restart, the rest of the
set is finished, after which error INSRE1-003 shows.

INS-RE1307

Reading error

Matching number of set is


not correct (related to
previous set).

OMR error. This error is generated if the


match number of the previous set does
not join in with the match number of the
current one (only with Flex code). The
set can - but does not need to - be
taken out of the collator. After a restart,
the rest of the set is finished, after
which error INS-RE1-003 shows.

INS-RE1308

Reading error

Parity of the marks read is


not correct. Reading window
incorrect? Reading marks
incorrect. Check reading
settings.

OMR error. This error is generated if the


parity of a read code is incorrect. The
set can - but does not need to - be
taken out of the collator. After a restart,
the rest of the set is finished, after
which error INS-RE1-003 shows.

INS-RE1309

Reading error

A mark is read at an illegal


position.

OMR error. This error code is generated


when a barcode line is read that can not
be in that particular position (too many
lines or inconsistent with other lines).
The set can - but does not need to - be
taken out of the collator. After a restart,
the rest of the set is finished, after
which error INS-RE1-003 shows.

6-20

rev. 1.0 - 12/2009

Service Manual

075.1

Error

Message

Cause

Information

INS-RE1310

Reading error

Incorrect marks read,


reading job settings,
slippage, reading head
adjustments needed.

OMR error. This error is generated if the


position of a barcode line is moved that
far, that it has arrived in the so called
forbidden zone. (The forbidden zone is
an area halfway two lines, that is
defined as a percentage of the line
distance.) The set can - but does not
need to - be taken out of the collator.
After a restart, the rest of the set is
finished, after which error INS-RE1-003
shows.

INS-RE1311

Reading error

Incorrect marks read,


OMR error. This error is generated if
reading job settings, reading more barcode lines are present than
window too long.
allowed for the used barcode (only for
OMR level 0). The set can - but does not
need to - be taken out of the collator.
After a restart, the rest of the set is
finished, after which error INS-RE1-003
shows.

INS-RE1312

Too many
documents

Set size exceeds maximum


number from reading job
settings, incorrect marks
read.

OMR error. Remove the set and press


Reset. To restart the system, press
Start. During collating through reading,
a set should always be completed.
However, a maximum set size is
indicated in the OMR setting menu
(attachments are included). When this
maximum size is reached, the collating
stops and this error is generated. This
does not happen during overlapping
supply from the feeders.

INS-RE1313

Reading error

No safety mark read.

OMR error. This error is generated when


a safety mark is not read. The set may
be removed from the collator. Pressing
Reset and Start will result in error INSRE1-003 Suspected set.

INS-RE1314

Reading error

Group start mark error.

OMR error. This error is generated when


a group start mark is not read. The set
may be removed from the collator.
Pressing Reset and Start will result in
error INS-RE1-003 Suspected set.

INS-RE1315

Reading error

Group end mark error.

OMR error. This error is generated when


a group end mark is not read. The set
may be removed from the collator.
Pressing Reset and Start will result in
error INS-RE1-003 Suspected set.

INS-RE1321

Reading error

The barcode could not be


read correctly.

Remove documents.

INS-RE1322

Reading error

The barcode is too long.

Remove documents.

rev. 1.0 - 12/2009

6-21

075.1

Service Manual

Error

Message

Cause

Information

INS-RE1323

Reading error

The barcode is too short.

Remove documents.

INS-RE1324

Reading error

Wrong start of set.

The new set does not start with N=1.


Remove documents.

INS-RE1325

Reading error

Sequence error.

N is not one more than the previous N in


the same set. Reset & start to finish set.

INS-RE1326

Reading error

M cannot be 0.

Remove documents.

INS-RE1327

Reading error

M changed in set.

Remove documents.

6.3.25 Machine state errors (SM)


Error

Message

Cause

Information

INS-SM1301

Envelope stoppage

Envelope lost in envelope


track.

Remove envelope.

INS-SM4301

Document transport Document transport failure.


failure

Remove documents check exit.

6.3.26 Stacker errors (STK)


Error

Message

Cause

Information

INS-STK000

Stacker almost full

About 10 envelopes to go
before message INS_STK001 appears.

Remove envelopes from stacker.

INS-STK100

Envelope stoppage

Unexpected mail set in


stacker transport path.

Time between the detection of the end


of the envelope at the inserter exit and
detection by the stacker sensor is too
long.

INS-STK101

Envelope stoppage

Stacker sensor covered too


long.

Remove all documents, check exit.

INS-STK300

Stacker full

Remove envelopes from


stacker.

INS-STK301

Envelope stoppage

Envelope too early at


stacker.

INS-STK400

Stacker Failure

Stacker cycle not finished in The photocell in the stack unit detects
time.
that the stacker cycle takes more than
0.75 s.
Remove all mail sets and check stacker.

6-22

Stacker is still busy when the envelope


arrives at the stacker sensor. Remove all
documents, check exit.

rev. 1.0 - 12/2009

Service Manual

075.1

6.3.27 Switches errors (SW)


Error

Message

Cause

Information

INS-SW1200

Cover open

Front cover open, cover


switches defect or loose,
envelope track sensors.

This error is generated if during a run


the front cover is opened.

INS-SW2200

Cover open

Collator cover open, cover


switches defect or loose,
envelope track sensors.

This error is generated if during a run


the collator cover is opened.

INS-SW3200

Cover open

Top cover open, cover


switches defect or loose,
envelope track sensors.

This error is generated if during a run


the top cover is opened.

INS-SW4200

Cover open

Stacker cover open, cover


switches defect or loose,
envelope track sensors.

This error is generated if during a run


the HCVS-1 cover is opened.

Cause

Information

6.3.28 System errors (SYS)


Error

Message

INS-SYS000

Preventive
Total counter equal to
maintenance needed Service Counter, Service
counter incorrect.

This error is generated if the next visit


service counter value is reached. The
message will appear at system start.

INS-SYS200

Serial number
already present in
ID tag

Machine's software and


identity are setup already.

This error is generated if a machine is


prepared in the factory and later on an
attempt is made to prepare the machine
again. Preparation (flashing and setting
serial number) should only be done on
pristine machines.

INS-SYS300

Technical failure

Connection board restarted. Reset to continue.

INS-SYS304

Technical failure

Communication failure
between inserter and
communication board.

INS-SYS501

Illegal configuration Illegal configuration


detected.

rev. 1.0 - 12/2009

Reset to continue.

This error is generated when the serial


number in the ID-tag 2994504Z does
not match the serial number in the Fram
of the main board. The machine is
blocked from operating, because the
counters in the Fram and the ID-tag
2994504Z do not match. See 4.3.9
Remove blockage on page 4-15.

6-23

075.1

Service Manual

Error

Message

Cause

Information

INS-SYS563

Technical failure

Incorrect software in
communication board or
inserter board.

At IN startup and configuration check.


Communication board is expected
because of service settings or licence.

INS-SYS580

Technical failure

System serial number


memorized in
communication board is not
the same as on ID tag. Most
likely because of exchanged
connection board from an
existing system.

OLS or INF error. At IN startup and


configuration check. Communication
board is configured on a different
inserter than the current inserter (based
on serial number). After reset error:
choose Continue without action or
Initialise communication board.

INS-SYS581

Technical failure

Communication board
OLS or INF error. At IN startup and
missing or defect, or internal configuration check. Also when INF info
cables or PCB defect.
is needed (INF job start, INF job
adjust). Communication board is
expected because of service settings or
licence. Cause: internal Cables, PCB
defect.

INS-SYS582

Technical failure

The installed modem could


not be detected as a legal
version.

OLS error. At IN startup and


configuration check a modem is
expected because of service settings or
licence.

6.3.29 Transport errors (TR)


Error

Message

INS-TR2110

Document transport Document path blockage,


failure
slippage, vertical track
photocells dusty.

This error is generated if the document


does not arrive in time at the collator
entry cell (if transport time between
leaving feeder and arriving at folder
entry exceeds 700 mm (750 pulses)).

INS-TR2290

Unexpected
documents in
vertical track

Document stoppage at
vertical track photocell.

Remove documents.

INS-TR3120

Envelope stoppage

Blocked envelope path,


slippage.

This error is generated if the envelope


or document transport from insert area
to closer sensor would take too long.
Longer than the time that meets 1200
flanks (approx. 600 mm).

INS-TR4110

Envelope stoppage

Transport failure between


envelope closing and
envelope exit.

INS-TR4120

Envelope stoppage
at exit

Blockage at envelope exit,


inserting failure, skewing,
slippage, exit blockage.

6-24

Cause

Information

This error is generated if the exit


detector is covered longer than 300 ms.

rev. 1.0 - 12/2009

Service Manual

6.4

075.1

Error handling franking machine

After pressing the i button in an error message screen, the display can show an error code.
The error format for franking machine errors is as follows: FRM-XXX-YYY. The inserter messages
are explained in 6.3 Error handling inserter on page 6-2. XXX is an abbreviation that indicates
a specific machine part. The following machine areas/prefixes apply:
XXX

Explanation

Reference

COM

Communication

6.4.1 Communication errors (COM) on page 6-26

EX

External

6.4.2 External errors (EX) on page 6-26

INF

insertn Frank

6.4.3 Insertn Frank errors (INF) on page 6-27

LIC

License

6.4.4 License errors (LIC) on page 6-34

SW

Cover switches

6.4.5 Cover switch errors (SW) on page 6-34

rev. 1.0 - 12/2009

6-25

075.1

6.4.1

Service Manual

Communication errors (COM)

Error

Message

Cause

Information

FRM-COM920

No communication
with franking
machine

Due to a time out INF


determined that
communication with the FM
has dropped. Caused by an
internal problem at the FM or
by disconnecting the serial
cable. Make sure the cable is
connected and restart the
job from the IN. If this fails,
switch off/on the FM or the
whole system.

At changing DS+MS job settings (for


which information from FM is needed),
job info or starting DS+MS job. In job
edit, after reset: continue the job edit
menu. The fields you cannot adjust and
knobs that belong to these fields are
grey. You can only select pass
through.

FRM-COM921

Communication
Indicates that the FM won't When pressing start key.
failure with franking accept commands and/or
machine
data from INF. Just wait and
try to start the job again or
switch off/on the FM.

FRM-COM922

Communication
Due to some fatal error
When pressing start key.
failure with franking conditions, communication
machine
with the FM has dropped in
Alayer. Try to start the job
again or switch off/on the FM
or the whole system.

FRM-COM923

Due to some fatal error


When pressing start key.
Communication
failure with franking conditions, communication
machine
with the FM has dropped in
Tlayer. Try to start the job
again or switch off/on the FM
or the whole system.

FRM-COM924

Communication
Due to some fatal error
When pressing start key.
failure with franking conditions, communication
machine
with the FM has dropped in
Dlayer. Try to start the job
again or switch off/on the FM
or the whole system.

6.4.2

External errors (EX)

Error

Message

Cause

FRM-EX1120

Envelope stoppage
between inserter
and franking
machine

This error is raised when an During run


envelope is not franked
within X seconds after
leaving the inserter. The X is
system and configuration
dependent. The envelope
might not be franked by the
FM.

6-26

Information

rev. 1.0 - 12/2009

Service Manual

6.4.3

075.1

Insertn Frank errors (INF)

Error

Message

Cause

FRM-INF000

Auto clean on
franking machine in
progress

Notification from the FM that When pressing start key.


the Auto Clean Cycle will be
started very soon.

FRM-INF001

Franking machine
not ready for
franking interface

At the FM is currently a
dialog displayed as a result
of an error (condition) that
occurred while INF was not
executing a job on the FM.
Probably the FM was used
stand alone. Look at the FM
user interface.

When pressing start key.

FRM-INF002

Auto clean on
franking machine is
finished

Notification from INF that


the Auto Clean Cycle has
been completed and the
franking process will be
resumed automatically.

When pressing start key.

FRM-INF003

Sealing on advanced An attempt is made to start


an FM job with sealing on
feeder of franking
machine is selected advanced feeder selected.
The user can only solve this
by modifying the FM job
(disable sealing) or
modifying the IN job.

FRM-INF200

Franking machine
already started

The FM cannot be started as When pressing start key.


it is already running.
Probably the user started the
FM manually or the FM was
not stopped in the previous
job. If not, switch off/on the
FM.

FRM-INF201

Franking machine
stopped via start/
stop key

This error is raised when the


user pressed the 'Stop'
button on the FM during a
run resulting in an
emergency stop. The last
envelopes(s) that left the
franking machine might not
be franked.

FRM-INF202

User PIN code


The FM has popped up a
When pressing start key.
required at franking dialog to enter the user PIN
machine
code. Job execution will be
blocked until the correct PIN
code has been entered.

rev. 1.0 - 12/2009

Information

When pressing start key.

6-27

075.1

Service Manual

Error

Message

Cause

FRM-INF203

Department PIN
code required at
franking machine

The FM job selected requires When pressing start key.


a department PIN code. INF
does not support this
feature. Job execution is
blocked. Either the PIN code
has to be removed or
another FM job has to be
selected.

FRM-INF204

Wrong PIN code


entered on franking
machine

The user has entered the


When pressing start key.
wrong PIN code and the FM
will go into 'sleep' mode. Job
execution is blocked.

FRM-INF205

User action required User action required at


at franking machine franking machine.

FRM-INF206

The franking
machine is in
supervisor mode

FRM-INF207

ZIP zone required at The FM has popped up a


When pressing start key.
franking machine
dialog to enter the ZIP Zone.
Job execution will be blocked
until a ZIP Zone has been
entered.

FRM-INF208

Franking machine
Franking interface software
job selected includes does not support this
correction mode
feature. Switch off correction
mode or select another
franking machine job

FRM-INF209

Franking machine
stopped via escape
key

FRM-INF210

Franking machine is The FM is being used 'stand


in stand alone mode alone'. As a result INF
cannot gain control over the
FM.

At changing DS+MS job settings (for


which information from FM is needed),
job info or starting DS+MS job. In job
edit, after reset: continue the job edit
menu. The fields you cannot adjust and
knobs that belong to these fields are
grey. You can only select pass
through.

FRM-INF300

Communication
A time-out occurred when
failure with franking attempting to wake up the
machine
FM from sleep/stand-by
mode. The FM did not wake
up in time. Try to start the
job again or switch off/on
the FM.

During run.

6-28

Information

See franking machine for more details.

An attempt is made to
When pressing start key.
execute a job while the FM is
in Supervisor mode. Exit
Supervisor mode at the FM
and try to start the job
again.

The user has aborted the


franking cycle by pressing
'ESCAPE' at the FM. The job
will be aborted.

When pressing start key.

rev. 1.0 - 12/2009

Service Manual

Error

Message

FRM-INF301

Due to an unsupported error When pressing start key.


Communication
failure with franking condition the FM refuses to
start. The user has to try to
machine
start the job from the IN
again. If this fails switch the
FM on/off.

FRM-INF302

An internal error
Due to an unsupported error During run or pressing start key.
occurred which
INF is unable to stop the FM.
blocks job execution Switch off/on the FM.

FRM-INF303

Communication
Due to an unsupported error During run.
failure with franking the FM did not complete the
machine
starting sequence in time.
Try to start the job again or
switch off/on the FM.

FRM-INF304

The franking
machine is in error
mode

INF is not able to configure When pressing start key.


the FM as an error has
occurred that has not yet
been solved and is not
specified. Please check the
FM user interface for any
message and close any
covers. Otherwise switch off/
on the FM.

FRM-INF305

The franking
machine is in busy
mode

INF is not able to configure When pressing start key.


the FM as the FM is busy for
some unknown reason.
Please wait a while,
otherwise switch off/on the
FM.

FRM-INF305

An internal error
For some reason the FM is
When pressing start key.
occurred which
busy and won't accept
blocks job execution commands from INF.
Possibly the FM was
manually started by the user.
Otherwise switch the FM off/
on.

FRM-INF306

Auto clean on
franking machine
time out

Notification from INF that


When pressing start key.
the Auto Clean Cycle takes
more time than expected.
Either the user wait until the
FM has actually finished Auto
Clean or switch the FM off/
on.

FRM-INF307

No active rate table

No active rate table,


When pressing start key.
probably Base only, activate
rate table.

rev. 1.0 - 12/2009

Cause

075.1

Information

6-29

075.1

Service Manual

Error

Message

Cause

Information

FRM-INF308

Internal error on
franking machine

The FM decided to execute


an emergency stop.
However, it did not provide
any further information for
the reason. Try to start the
job again or switch off/on
the FM.

During run or pressing start key.

FRM-INF309

Manual clean of
An attempt to force to clean When pressing start key.
cartridge on franking the cartridge manually
machine failed
failed. Not user solvable! Try
again.

FRM-INF310

More envelopes
have been franked
than sent by the
inserter system

Possible presence of
envelopes in FM from
previous job, or envelopes
manually put onto the FM
during the job.

FRM-INF311

Selecting franking
machine job failed

Unable to select a job at the During run or pressing start key.


FM due to an unsupported
error. Try to restart the job
again or switch off/on the
FM.

FRM-INF312

Selecting franking
machine job failed

Inserter job is coupled to a


non-existing FM job (the
specified job ID is empty).
Update the job definition at
the IN or create a job at the
FM.

FRM-INF313

Wait position
occupied

INF received data for the


When pressing start key.
next envelope while the
current envelope has not yet
left the waiting position.
Restart the job.

FRM-INF314

Franking machine
job selected includes
Dynamic batch
mode

An attempt is made to start When pressing start key.


an FM job from the IN. The
FM job includes Dynamic
Batch Mode which is not
supported when KEOPS is in
Inserter Mode. This job is
blocked by INF. Either the
user has to switch off
Dynamic Batch Mode or
has to select another job.

FRM-INF315

The franking value


exceeded the 'High
value threshold

A job was started in which


When pressing start key.
the franking value exceeded
the 'High value' threshold.
The user has to confirm this
high value at the FM by
either pressing 'OK' or
'ESCAPE'.

6-30

During run.

At changing DS+MS job settings (for


which information from FM is needed),
starting DS+MS job. In job edit, after
reset: continue the job edit menu. The
fields you cannot adjust and knobs that
belong to these fields are grey. You can
only select pass through.

rev. 1.0 - 12/2009

Service Manual

Error

Message

FRM-INF315

Weight exceeds limit Check weight values in job


settings.

FRM-INF316

Envelope measures

FRM-INF317

Concerns incorrect set up of When pressing start key.


An internal error
the option. An attempt was
occurred which
blocks job execution made to set the franking
mode to an invalid or no
longer supported mode. As a
result the current franking
mode is retained. Probably
caused by incompatible
software versions of Inserter
and INF module.

FRM-INF318

Sealing on advanced An attempt is made to start It is recommended to seal with the


feeder of franking
an FM job with sealing on the inserter. This warning is generated when
machine is selected MMF/AF selected. This can
pressing the start key.
be overruled through the
service menu setting. See
4.3.10 Sealing on franking
machine on page 4-15.

FRM-INF900

Internal error on
franking machine

At the FM an error has


During run or pressing start key.
occurred that permanently
blocks execution of the
current run. The user has to
look at the UI of the FM for
more details. Best case, the
job can be started again
after resolving the problem.
Worst case the FM has to be
switched off/on.

FRM-INF901

Error or warning on
franking machine

At the FM an error has


During run or pressing start key.
occurred that temporarily
blocks execution of the
current run. The user has to
look at the UI of the FM for
more details. After solving
the problem, the run will be
resumed automatically.

FRM-INF902

Communication
INF received incorrect
failure with franking envelope data (unknown
machine
hopper or invalid hopper
data). Remove any
envelopes from the system
and try to start the job
again.

rev. 1.0 - 12/2009

Cause

075.1

Information
When pressing start key.

Invalid envelope measure for When pressing start key.


PPC management.

When pressing start key.

6-31

075.1

Service Manual

Error

Message

FRM-INF903

INF received incorrect


Communication
When pressing start key.
failure with franking envelope data (unknown
thickness or invalid thickness
machine
data). Remove any
envelopes from the system
and try to start the job
again.

FRM-INF904

An internal error
Unable to make some
During run.
occurred which
settings at the FM due to an
blocks job execution unsupported error. Try to
restart the job again or
switch off/on the FM.

FRM-INF905

An internal error
Unable to retrieve settings
occurred which
from the FM due to an
blocks job execution unsupported error. Try to
restart the job again or
switch off/on the FM.

During run.

FRM-INF906

An internal error
Unable to configure the
occurred which
'Base' (FM) due to an
blocks job execution unsupported error. Try to
restart the job again or
switch off/on the FM.

When pressing start key.

FRM-INF907

An internal error
Unable to configure the
During run or pressing start key.
occurred which
'Advanced Feeder' (AF) due
blocks job execution to an unsupported error. Try
to restart the job again or
switch off/on the FM.

FRM-INF908

Internal failure on
franking machine

FRM-INF909

Communication
The FM did not complete the When pressing start key.
failure with franking stop sequence in time. The
machine
FM might have to be
switched off/on in order to
continue with another job.

FRM-INF910

Communication
During job execution the FM When pressing start key.
failure with franking terminated the job
machine
unexpectedly for some
unknown reason. Try to
restart the job again or
switch off/on the FM.

6-32

Cause

Information

Unable to configure the


When pressing start key.
'Dynamic Scale' (DS) due to
an unsupported error. Try to
restart the job again or
switch off/on the FM.

rev. 1.0 - 12/2009

Service Manual

Error

Message

Cause

FRM-INF911

Communication
failure

INF received an envelope


When pressing start key.
from the IN but the data for
that envelope was either lost
or never delivered to INF.
INF is unable to recover from
this situation. Remove the
envelope from the waiting
position and start the job
again.

FRM-INF912

Unknown envelope
detected

INF has detected a physical When pressing start key.


envelop at the wait position,
but did not receive any data
for it. The envelope (if any)
has to be removed.

FRM-INF913

Unknown envelope
detected

INF has detected a physical When pressing start key.


envelop at the wait position,
but was not notified about its
arrival. The envelope (if any)
has to be removed.

FRM-INF914

An internal error
INF is busy and cannot
When pressing start key.
occurred which
accept any commands. An
blocks job execution attempt was made to change
settings while INF is busy.
Internal error, not user
solvable. Just try again later
and ultimately switch off/on
the whole system.

FRM-INF915

FIFO Overflow

FIFO Overflow for PPC


variable mode.

When pressing start key.

FRM-INF916

Rate calculation

Rate calculation failure.

075.1

When pressing start key.

rev. 1.0 - 12/2009

Information

6-33

075.1

6.4.4

Service Manual

License errors (LIC)

Error

Message

FRM-LIC300

An internal error
Concerns incorrect set up of When pressing start key.
occurred which
the option. The INF level is
blocks job execution set to INF_LEVEL_NO_INF.
Probably caused by
incompatible software
versions of Inserter and INF
module. Internal error, not
user solvable.

6.4.5

Cause

Information

Cover switch errors (SW)

Error

Message

Cause

Information

FRM-SW5200

Cover open on
franking machine

Franking machine cover


open, cover switches defect
or loose? Close the cover.
This error is only generated
when the cover switch is
activated. It does not
register if the cover is open
or closed.

During run or pressing start key.

6-34

rev. 1.0 - 12/2009

Service Manual
7

Upgrading and installing accessories

7.1

075.1

Reading (barcode en OMR)

See separate document: Mounting instruction no. 73.

7.2

MaxiFeeder

See separate document: Mounting instruction no. 82.

7.3

Insertn Frank

See separate documents: Mounting instructions no. 84, 85 and 109.

7.4

Side exit

See separate document: Mounting instruction no. 67.

7.5

High Capacity Vertical Stacker

See 10.5 High Capacity Vertical Stacker on page 10-43 and separate document: Mounting
instruction no. 113.

7.6

Mail Piece Production Control (MPPC)

See separate document: Mounting instruction no. 100.

7.7

Online services

See the procedure below and the separate mounting instruction: MI97 Communication
package.
This section describes how to connect an OLS machine in the field to the server.
7.7.1

Preparations

Check that following preparations are done before installing an OLS machine in the field.
1
2

3
4

The back office team has prepared the system for declaration on the server. The system
has the status allocated on the OpCoweb.
The system is OLS compatible. This means that the system is equipped with the connectivity
hardware:
communication board
connection board with modem
telephone cable

OLS is enabled on the system: from the Main menu, select Supervisor menu (pin 4351),
Total system, System settings, Configuration, Edit. Check if Online Services is
enabled.
A analogue telephone line is available.

rev. 1.0 - 12/2009

7-1

075.1

7.7.2

Service Manual

Connect the system

To connect the system, set the online service parameters.


1

From the Main menu, select Supervisor menu (Pin 2546), Online Services,
Configuration.

Note: Do not change the Dial tone detection, the Phone number and the Country.
These items are predefined.
2

Ask the customer if a prefix is necessary to dial to an external number. If that is necessary
enter the prefix.

Go to the second Configuration menu.

4
5

Set the date to the actual date.


Set the time to the actual time.

Note: Do not change the Modem volume. The modem volume is predefined.
6

Press the OK button.

Now the system is ready for initial declaration:


1
2

From the Main menu, select Supervisor menu (Pin 2546), Online Services,
Connection, Connect.
The initial declaration call is finished if the connection status displays Disconnected.
Press the i button to see the status of the system.
System status: pending declaration if initial declaration was successful.
System status: undeclared if initial declaration has failed (see 6.2 Troubleshooting
Online Services on page 6-2).

Now the system is ready for declaration and for transferring data:
1

From the Main menu, select Supervisor menu (Pin 2546), Online Services,
Connection, Connect.
The declaration call is finished if the connection status displays Disconnected.

7-2

rev. 1.0 - 12/2009

Service Manual

075.1

Press i button to see the status of the system.


System status: declared if declaration was successful. The machine is acknowledged
by the server.
System status: pending declaration if the machine is waiting to be declared or
declaration has failed (see 6.2 Troubleshooting Online Services on page 6-2).

If the machine status is undeclared the machine is not acknowledged by the server. The initial
declaration has failed.

rev. 1.0 - 12/2009

7-3

075.1

7-4

Service Manual

rev. 1.0 - 12/2009

Service Manual
8

Technical specifications

8.1

075.1

Machine specifications

Model:

075.1, M5500, Carat

Max, FPi 4500, FD6304

Type:

Fold and insert system for medium office use

Noise level:

< 66 dB(A) (according to ISO 11202)

Power consumption:

100V AC / 50 Hz / 5.0 Amps (voltage tolerance: +6%/-10%)


115V AC / 60 Hz / 5.0 Amps (voltage tolerance: +6%/-10%)
230V AC / 50 Hz / 2.5 Amps (voltage tolerance: +10%/-10%)

Processor:

32 bits ARM7

Memory:

16 Mb SDRAM and 4 Mb flash ROM

Approvals:

EMC Certificate conform EMC-Directive


FCC Certificate conform 47CFR, part 15
CB Certificate conform IEC 60950-1
UL Listed I.T.E. (Information Technology Equipment), conform
UL-IEC 60950-1, file E153801
Conform NEN-EN-IEC 60950-1 and derivatives

rev. 1.0 - 12/2009

8-1

075.1

Service Manual

Available models:

DS-75 Expert

3 standard feeders

DS-75 Special

2 standard feeders
1 special feeder at the bottom

DS-75 Expert + High Capacity (Document) Feeder 1 standard feeder


1 high capacity (document) feeder

DS-75 Special + High Capacity (Document) Feeder 1 special feeder


1 high capacity (document) feeder

DS-75 High Capacity Expert

1 standard feeder
1 high capacity (document) feeder
1 high capacity vertical stacker

DS-75 High Capacity Special

1 special feeder
1 high capacity (document) feeder
1 high capacity vertical stacker

DS-75 Max Capacity

1 high capacity (document) feeder


1 high capacity BRE/insert feeder (MF-2)
1 high capacity vertical stacker

About the standard (automatic) and special feeder:

Standard feeder: typically for normal address carrier documents from laser printers, impact
printers, copiers and also some glossy papers depending on a test

Special feeder: for special papers such as glossy papers, small booklets prefolded inserts,
but also for normal paper

8-2

rev. 1.0 - 12/2009

Service Manual

8.2

075.1

Documents

Paper length:

minimum

130 mm
140 mm

maximum (no fold, no insert)

242 mm

maximum (no fold)

236 mm

maximum with fold

230 mm

minimum

60 gr/m2

maximum without folding:

250 gr/m2

maximum with fold

Brochures:

356 mm (14")

minimum maxiFeederTM

Paper weight:

90 mm

maximum

Paper width:

minimum

170 gr/m2

maximum thickness (no fold)

1 mm

if flexible and back/fold leading into feeder

Reply envelopes:

80 gr/m2

minimum size

90x130 mm (height x width),


with MF-2: 90x140

maximum size

Set thickness:

minimum weight

156x236 mm (height x width)

Max. number of sheets to be folded:


10 x 80 gr/m2 (single fold)
8 x 80 gr/m2 (letter fold, Z-fold)
4 x 80 gr/m2 (double parallel fold)
Max. set thickness to be conveyed through folder: 2.5 mm
Max. number short documents not to be folded is 25 sheet of 80 gr/m2.
Depending on paper quality this is limited to 12-25 sheets of 80 gr/m2.
Max. thickness of a set after folding is: 2.5 mm

Note:
When sets are at maximum thickness (e.g. 7-8 sheets letter fold), it might be necessary to tune the fold
settings for good inserting and exit (especially side exit). For example, for A4: fold not 108/216 but 105/
210.

rev. 1.0 - 12/2009

8-3

075.1

Set height:

Service Manual

max.set height 156 mm (or envelope height -/-6)mm)


max set height (with not inserting) 203 mm [A], and mutual difference address
fold and set height/residual length max. 50 mm [B].
No fold:

Single fold:

Letter fold:

Z fold:

min. set height 84 mm


min. set height (with not inserting) 102 mm

Kinds of paper:

standard feeder

MC shiny up to and including mat

standard feeder

Recycled paper

8-4

Normal

standard feeder

rev. 1.0 - 12/2009

Service Manual

075.1

Booklets

standard feeder

Prefolded paper: A3 double to A4

special feeder

A4 folded to A5 or 4" or booklets

special feeder

Reply Envelopes

special feeder

Notes:
Powdered paper, NCR, satinated paper will not be able to achieve the reliability of the standard feeder.
Prefolded and reply envelopes can possibly be processed by the standard feeder. This should be tested
with each customer application.

8.3

Envelopes

Height:

minimum

90 mm

maximum

162 mm

maximum at presentation with open flap: Envelope + flap max. 165 mm

Width:

minimum

160 mm

minimum

Set width +12 mm with single sheet,


increasing to +28 mm for 8 sheet multiple
fold

maximum

248 mm

minimum

32 mm (in middle)

maximum

envelope height minus 32 mm

minimum

10 mm on 43 mm from the center

maximum

35 mm on 43 mm from the center

maximum dcollet in the center

75 mm

minimum paper weight:

80 gr/m2

maximum paper weight:

120 gr/m2

Flap height:

Dcollet:

Paper grade:

rev. 1.0 - 12/2009

8-5

075.1

Service Manual

Insert specifications

A
Minimum size

mm

160

90

32

10

130

84

60 g/m2

3.5

1.25

0.4

5.1

3.3

60 g/m2

inches 6.3
Maximum size

mm

248

inches 9.7

162

B-32

35

A-12**

B-6

2.5*

6.38

B-1.25

1.4

A-0.47**

B-0.2

0.1

* Booklets up to approximately 1 mm (0.04 inch) thickness, depending on stiffness


** When insert is more than 1 mm (0.04 inch): A-15 mm / A-0.6 inch

Notes

Maximum insert specifications are based on single sheets. When multiples are handled,
more room inside the envelope is needed depending on the application.

The specification of the paper handling equipment is often wider than that of the envelopes
and documents handled. The condition of material handled will limit the specified
environmental conditions.

We recommend that materials to be handled are stored at a temperature of 20C (68F)


with a relative humidity factor of 50%. If difference in temperature occurs between store
room and mailing area, the material has to be stored near the system at least 24 hours
before use.

Self-copying paper may cause rubber parts to wear quicker. The rubber used in this system
has the best resistance to Wiggins Teape material.

8.4

Capacity feeders and exit options

Capacity feeder hopper:

325 sheet 80 grm/m2, this is approximately 3.7 cm

Capacity high capacity feeder:

725 sheet 80 grm/m2, this is approximately 7.3 cm

Capacity BRE maxiFeederTM:

325 reply envelopes

Capacity envelope hopper:

160-170 mm (325 empty envelopes 80 gr/m2)

Capacity envelope exit options:


Catch tray

100 env C5/6 with 1xA4 80 gr/m2 multiple fold

Side exit catch tray

225 env C5/6 with 1xA4 80 gr/m2 multiple fold

High Capacity Vertical Stacker

400 env C5/6 with 1xA4 80 gr/m2 multiple fold

8-6

rev. 1.0 - 12/2009

Service Manual

8.5

075.1

Fold types

The 075.1 has two folding tables, both in upwards position seen from the paper path. The
following folds are possible:

No Fold

Single fold

Letter fold

Double parallel

Z fold
Feeding instructions:
Address/ Fold type

Z-fold

Other folds

Address carrier loaded in

Bottom station or Top station

Top station

Address face...

Down

Up

Address position

Trailing

Leading

Folding table limitations:


Maximum depth 1st folding table

255 mm

Maximum depth 2nd folding table

150 mm

Minimum depth in 1st and 2nd folding table

25 mm

Minimum distance from top of document to first


fold (address part)

Letter fold

75 mm

Maximum difference between 2 folds and the top


of document to first fold (address part)

Letter fold

105 mm

8.6

Processing speed

There are 3 fixed stop positions on the collator.


These positions are:

a: A5

b: A4

c: 14"
The actual stop position used depends on the set length of the current job, and will be
automatically activated:

When the set length is 148 or shorter stop, a will be used.

When the set length is 149 to 297 stop, b will be used.

When the set length is 298 to 356 stop, c will be used.

rev. 1.0 - 12/2009

8-7

075.1

Service Manual

System speed per job:


Feeder 3:

1xA4

Feeder 2:

1xA4

1xA4

3xA4

1xA4

2xA4
2xA4

Feeder 1:

1xA5

1x11"

1xA4

1x14"

1x100

1xA4

1xA4

1x100

1x100

Fold:

E 108

W 99/
198

W 108/
216

DP 99/
198

W 96/
204

W 108/
216

W 108/
216

W 106/
212

W
106/
212

Collator at:

Mode:

Doc offset:

50

50

50

50

50

50

50

50

50

BRE offset:

yes

yes

yes

yes

yes

yes

yes

yes

yes

Envelope:

C5/6
(114)

#10
(105)

C5/6
(114)

#10
(105)

C5/6
(114)

C5/6
(114)

C5/6
(114)

C5/6
(114)

C5/6
(114)

Output/hour:

3500

3060

3000

2500

2650

2650

2200

900

900

8.7

Configuration dimensions

Length:

770 mm

on covers

1120 mm

including hopper (90 mm) and feeder trays (265 mm)

1270 - 1360 mm

including standard exit (catch tray)

1200 mm

including side exit

1360 mm

including high capacity vertical stacker

Width:

455 mm

(the optional side exit is 90-195 mm outside side cover)

Height:

720 mm
800 mm

8.8

including high capacity vertical stacker

System operation control

Features

Performance

Number of jobs programmable

25

Screen size

20mm * 90 mm

Screen resolution

Resolution: 320 * 240 pixels

Screen technology

Full color touch screen

8-8

rev. 1.0 - 12/2009

Service Manual

8.9

075.1

Other general specifications

Features

Performance

Operating temperature

10C - 40C

Operating humidity

30% - 80%

Weight

Whole system: 73 kg

8.10

Quality

Maximum volume per month: 40,000 envelopes

8.11

Reading (Optical Mark Recognition)

8.11.1 Concept

One track OMR code


Factory fitted as well as field upgradeable
Available levels: Basic, Advanced and Flex

8.11.2 Format of the marks


Minimum character length: 6.3 mm or 3 characters.
8.11.3 Reading head location
The reading head is located in the vertical transport area between the first and second feeder.
That means that the 075.1 can read from feeder 2 and 3.
8.11.4 Options
Flexible OMR is also available on the 075.1.
Flexible OMR enables the customer to read the OMR codes of different suppliers. This means that
the system can comprehend and execute the command in the different codes of for instance
Pitney Bowes and/or PFE. The flexible OMR dongles can contain up to 9 different codes.

8.12

Reading (Barcode)

8.12.1 Concept

1D vertical bar code


Factory fitted as well as field upgradeable
Available levels: Basic, Advanced and Flex

8.12.2 Format of the code


The minimal height of the code is 9 mm (0.35 inch).
The minimal thickness of a bar in de code is 0.25 mm (0.01 inch).
8.12.3 Reading head location
The reading head is located in the vertical transport area between the first and second feeder.
That means that the 075.1 can read from feeder 2 and 3.
8.12.4 Options
Flexible BCR is also available on the 075.1.

rev. 1.0 - 12/2009

8-9

075.1

Service Manual

Flexible BCR enables the customer to read the BCR codes of different suppliers. This means that
the system can comprehend and execute the command in the different codes of for instance PFE.

8.13

Product customization per country / organization

There is no product customization per country specific to 075.1 except for the usual differences,
for example voltage and plugs.
The 075.1 will also be built under the product names: M5500, Carat

8-10

Max, FPi 4500, FD6304.

rev. 1.0 - 12/2009

Service Manual
9

075.1

Illustrated parts list

This section contains information on the available spare parts. Use the figures and
accompanying tables in this section to find the appropriate part numbers.
Note
Each figure has its own title. Therefore, to quickly find the figure you need, you can refer to the
Table of Contents at the front of this manual.

rev. 1.0 - 12/2009

9-1

075.1

9.1

9-2

Service Manual

Covers, frames, and external parts 1/3

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6

Cover plate LH (lower)


Round head screw M4 x 8
Strip
Washer 12x5.2x0.7mm
Bellows
User's guide

2825411L
2054313J
2970051C
2430535G
2041304H
2894393S

1
1
1
2
1
1

2894394T

2894395U

2894396V

2894397W

Grommet
Hinge bracket
Screening plate
Magnetic clip
Countersunk head screw m4x10
Decorative cover LH
Decorative cover RH
Round head tapping screw
Round head screw m4x10
Round head screw m4x8
Cover plate RH (lower)
Nut m4
Self-locking clip
Hex. head screw M4x8
Front cover tower 3 st.
Front cover tower 3 st.

2120851U
2994060M
2964613N
2957091C
2053875C
2994066T
2994068V
2453858B
2454314B
2453868M
2825412M
2451902P
2052602B
2053880H
2825428D
2825456H

1
1
1
2
2
1
1
2
2
10
1
8
2
5
1
1

Front cover tower 3 st.


Front cover tower HCF
Front cover tower HCF

2825457J
2825439Q
2825458K

1
1
1

Front cover tower HCF


Front cover LH
Front cover LH
Front cover LH
Front cover LH
Front cover LH
Front cover LH
Reinforcement plate
Main board cover assy.
Magnet mounting plate
Sealing liquid tray
Envelope tray (assy.)

2825434K
2825440R
2825441S
2825442T
2825433J
2825435L
2825424Z
2994059L
2994027C
2994076D
2825250T
2989259L

1
1
1
1
1
1
1
1
1
1
1
1

7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

22

23
24
25
26
27

rev. 1.0 - 12/2009

Remarks

Neopost brand,
EN-FR-ES
Neopost brand,
IT-FR-DE
Neopost brand,
FR-DE-NL
2nd channel
brand,
EN-FR-ES
2nd channel
brand,
EN-DE-NL

Neopost
Hasler, blank
Formax, Satas
Francotyp
Neopost
Hasler, blank
Formax, Satas
Francotyp
Neopost
Hasler
Formax
Satas
Francotyp
blank

9-3

075.1

Service Manual

Number

Description

Part number Quantity

28
29

Slide complete
Side cover RH

2042320R
2825413N

1
1

30

Side cover RH
Cover plate

2825423Y
2964612M

1
1

9-4

Remarks
Neopost,
Hasler, blank
Formax, Satas
Francotyp

rev. 1.0 - 12/2009

Service Manual

075.1

Intentionally blank

rev. 1.0 - 12/2009

9-5

075.1

9.2

9-6

Service Manual

Covers, frames, and external parts 2/3

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Bottom cover collator area


Cover dark edge LH
Cover dark edge RH
Top cover bracket
Nut m4
Countersunk head screw m4x10
Stud
Hex. head screw M4x8
Float magnet
Sealing liquid tray
Round head screw m4x8
Moistening cloth
Sealing liquid sensor assy.
Clamping strip
Support plate
Bottom plate
Collator area cover
Top cover assy.
Power supply cover plate
Communication unit assy. (standard)
Communication unit assy. (extended)
Screwlock

2825403C
2825401A
2825402B
2825404D
2451902P
2053875C
2989219U
2053880H
2825255Y
2825250T
2453869M
2040306T
2825246P
2043201J
2260452M
2989217S
2825419U
2825417S
2994020V
2994081J
2994079G
2994070X

rev. 1.0 - 12/2009

Remarks

1
1
1
2
8
3
3
7
1
1
17
1
1
6
1
1
1
1
1
1
1
1

9-7

075.1

9.3

9-8

Service Manual

Covers, frames, and external parts 3/3

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13

Transparant plate
Top cover upper unit
Ejot screw 2,5 x 8
Loc cover
Hex. head screw M4x8
Nut m4
Screw 5.0x14
Round head screw M4x8
Countersunk head screw m4x10
Vertical transport cover
Stop button assy.
Start button assy.
Reinforcement plate assy.

2994067U
2825400Z
2994088R
2994071Y
2053880H
2451902P
2989183G
2053868V
2453875U
2825405E
2825452D
2825451C
2994069W

rev. 1.0 - 12/2009

Remarks

1
1
1
1
4
2
4
3
2
1
1
1
1

9-9

075.1

9.4

9-10

Service Manual

Envelope hopper 1/2

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

Washer 14x8,2x0,8mm
Side guide RH
Front plate RH
Round head screw M4x6
Flanged bush
Front plate LH
Countersunk head screw M4x10
Spring clip 7-9mm
O-ring
Flat spring
Thumb wheel
Side guide LH
Nut m4
Adjustment axle
Locking spring
Bottom cover
Pressure spring
Countersunk head screw m4x10
Countersunk head screw m4x6
Bracket for axle
Round head screw M4x16
Envelope support (assy.)
Feed table (assy.)
Front plate (assy.)

2040141W
2825445W
2994355U
2053866T
2994379U
2994354T
2994375Q
2052442K
2994376R
2994374P
2241358X
2825444V
2451902P
2994372M
2036336H
2994363C
2043091U
2053875C
2454211U
2994373N
2053871Y
2825447Y
2825443U
2809106B

rev. 1.0 - 12/2009

Remarks

1
1
1
10
2
1
1
1
1
2
1
1
4
2
2
1
1
7
4
1
2
1
1
1

9-11

075.1

9.5

Service Manual

Envelope hopper 2/2

RH
27
26
25
24

23 22 21 20

19 18 17 16 15

8
9

14 13 12 11

10

LH

9-12

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

Spring clip 6 - 8 mm
Damper
Inside frame RH
Hinge axle
Inside frame (upper unit) RH
Damper suspension axle
Inside frame (upper unit) LH
Inside frame LH
Foot assy.
Buffer
Envelope feed axle
Jogger roller
O-ring
Feed roller 42 mm
Set screw M4x6
Conductive bearing 10 mm
Washer 16 x 10.2 x 0.8 mm
Spring clip 10 - 14 mm
Cyl. pin 2.5 x 12
Slip clutch CCW 8mm
Timing belt
Pulley 15T (assy.)
Washer 14x8.2x 0.8 mm
Spring clip 8 - 11 mm
Support plate
Lower damper pin RH
Round head screw M4x8
Spring clip 11-15 mm

2052446P
2964140V
2989139L
2964114T
2989162K
2964120Z
2989163L
2989136H
2994108M
2994072Z
2989410T
2975952Z
2041876D
2732731U
2082802K
2042426B
2040143Y
2052483C
2052347L
2957127Q
2951316M
2930554K
2040141W
2052454X
2964185S
2964117W
2053868V
2052473S

rev. 1.0 - 12/2009

Remarks

4
2
1
1
1
1
1
1
4
2
1
2
2
1
1
2
3
2
1
1
1
1
2
1
1
1
7
4

9-13

075.1

9.6

9-14

Service Manual

Envelope separation

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Stop plate
Lever
Separation adjustment lever
Hinge joint
Round head screw M4x16
Flat spring
Frame plate
Round head screw m3x6
Flanged bush
Round head screw m3x8
Separation roller support
Separation roller axle
Spring clip 5-7mm
Lifting axle
Separation roller (assy)

2809096R
2809098T
2809099U
2809097S
2053871Y
2809101W
2825201S
2454302P
2809160H
2053865S
2809094P
2809095Q
2052466K
2809100V
2994358X

rev. 1.0 - 12/2009

Remarks

1
1
1
1
4
1
1
4
4
2
1
1
2
1
1

9-15

075.1

9.7

Service Manual

Lower envelope track 1/2

10 11 12 13
1

RH

9
14 15 16 17 18 19 20 21 22

44
(10)
45
46

47
48
49

25 24 23

43 42 41 40 39

LH

55 54 53 52 51 50

38 37 36 35 34 33 32 31 30

9-16

29 28 27 26

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51

Inside frame LH
Envelope guide plate LH
Hex. head screw M4x8
Spring clip 10 - 14 mm
Washer 16 x 10.2 x 0.8 mm
Conductive bearing 10 mm
Upper frame envy. track
Cyl. pin 2.5 x 16
Transportation roller 30 mm
Sensor (including holder)
Bracket
Nut M4
Pan head tapping screw
Brush lifter
Tension spring
Clutch shaft
Transportation axle
Freewheel transportation axle
Transportation axle
Envelope guide plate RH
Fixing plate envelope track
Inside frame RH
Round head screw M4x8
Round head screw M4x25
Lifting bracket
Tension spring
Nut M4 (self-locking)
Draw bar
Clamping ring 3 mm
Spacer
Lever
Lifting frame
Washer 9 x 4.3 x 0.8 mm
Mounting plate
Lifting roller
Round head screw M4x16
Round head screw M4x25
Sleeve
Pressure spring 0.85 mm
Pressure spring 0.7 mm
Air hose
Spring clip 9 - 12 mm
Air tube plug
Air hose connector
Bracket
Pan head tapping screw
Hinge axle
Lower frame env. track
Led (including holder)
Transportation roller 30 mm
Spring clip 8 - 11 mm

2825315L
2964259U
2053880H
2052483C
2040143Y
2042426B
2994303Q
2052346K
2995420D
2042453E
2964148D
2451902P
2453855Y
2043020V
2031175G
2964172D
2964175G
2964188V
2964171C
2964260V
2957304Z
2825316M
2053868V
2053872Z
2043022X
2033559Q
2053621N
2964128H
2052463G
2041098T
2964132M
2964124D
2453702P
2964125E
2964126F
2053871Y
2454318F
2041216R
2431112H
2031111Q
2241308V
2052455Y
2241302P
2041323C
2433429W
2453853W
2964322K
2964123C
2042452D
2951312H
2052454X

rev. 1.0 - 12/2009

Remarks

1
1
7
6
6
8
1
14
6
2
1
2
2
1
1
1
1
1
1
1
1
1
4
1
1
1
2
1
4
1
1
1
1
1
1
1
1
1
2
4
1
1
2
2
1
1
1
1
1
8
7

9-17

075.1

Service Manual

Number

Description

Part number Quantity

52
53
54
55

Washer 14 x 8.2 x 0.8 mm


Conductive bearing 8 mm
Axle
Axle for pressure rollers

2040141W
2042425A
2964153J
2964152H

9-18

Remarks

6
6
1
2

rev. 1.0 - 12/2009

Service Manual

075.1

Intentionally blank

rev. 1.0 - 12/2009

9-19

LH

9 10

9-20
30 29

26

27

28

31

32

25 24 23

35 36

22 21 20 19

13

12

11

18

17

16

15

14

9.8

33

34

RH

075.1
Service Manual

Lower envelope track 2/2

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

Sleeve
Pin
Conductive bearing 10 mm
Washer 16 x 10.2 x 0.8 mm
Rubber roller
Spring clip 9 - 12 mm
Spring clip 10 - 14 mm
Transportation axle
Cyl. pin 2.5 x 16
Transportation roller 30 mm
Round head screw M4x8
Round head screw M4x6
Hex. head screw M4x8
Countersunk tapping screw
Bracket
Sensor (including holder)
Mounting plate
Hinge axle
Pressure spring 0.85 mm
Spring clip 7 - 9 mm
Lifting plate
Clamping ring 3 mm
Connecting rod
Hinge pin
Axle for pressure rollers
Washer 9 x 4.3 x 0.8 mm
Pressure spring
Pressure roller (assy.)
Pan head tapping screw
Flap scraper
Nut M4
Washer 12 x 5.2 x 0.7 mm
Bracket
Led (including holder)
Flap opener
Draw bar

2964370K
2964371L
2042426B
2040143Y
2964190X
2052455Y
2052483C
2964171C
2052346K
2041827C
2053868V
2053866T
2053880H
2053856H
2964555C
2042453E
2964553A
2964554B
2431112H
2052442K
2964129J
2052463G
2964130K
2964131L
2964170B
2453702P
2033551G
2964556D
2453853W
2964145A
2451902P
2430535G
2964148D
2042452D
2964144Z
2964128H

rev. 1.0 - 12/2009

Remarks

2
1
6
5
1
2
3
1
4
4
12
4
5
1
1
1
1
1
2
2
2
4
2
2
1
4
4
4
1
1
1
1
1
1
1
1

9-21

LH

9-22

57

58

52 51

59 60 61

9 10 11 12 13

50 49 48

47 46 45 44

62 63 64 65

14 15 16 17 18 19 20

36

35

34

43 42 41 40 39 38 37

33

32

RH

21 22 66 23 24 25 26 27 28 29 30 31

9.9

56 55 54 53

075.1
Service Manual

Insert table and upper envelope track

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52

Microswitch (incl. lever)


Washer 7 x 3.2 x 0.5 mm
Round head screw M3 x 12
Spacer 15 x 10.4 x 3 mm
Cover
Frame axle
Pan head tapping screw
Protecting plate
Sensor (including holder)
Led (including holder)
Lock washer 5/32
Round head screw M4 x 8
Countersunk head screw M4 x 10
Upper sealing roller 36 mm
Mounting plate
Lower sealing roller (assy.)
Pressure spring
Washer 16 x 10.2 x 0.8 mm
Conductive bearing 10 mm
Pressure spring 0.7 mm
Pressure spring 1.1 mm
Round head screw M4 x 6
Conductive bearing 6 mm
Tension pin 2 x 12
Round head screw M4 x 16
Actuator disc
Nut M4
Clamping ring 3 mm
Nut M4 (self-locking)
Draw bar
Tension spring
Mounting bracket
Solenoid
Lever for finger
Pressure spring
Finger
Cross connection (incl. cork rubbers)
Cork rubber
Leaf spring
Finger slide
Pressure spring
Hex. head screw M4 x 8 (synthetic)
Knurled nut
Adjustable finger
Pulley axle (assy.)
Connecting ring
Transportation axle (assy.)
Transportation table (assy.)
Transportation roller
Cyl. pin 2.5 x 16
Transportation roller 30 mm
Transportation roller 30 mm
Pulse disc axle (assy.)

2989056Z
2453739C
2454305S
2040858T
2957152R
2957153S
2453853W
2957313J
2042453E
2042452D
2052431Y
2053868V
2453875U
2732648H
2957204V
2989433S
2031191Y
2040143Y
2042426B
2031111Q
2031115U
2454312Z
2042424Z
2053315U
2454316D
2964061N
2451902P
2052463G
2053621N
2964062P
2033504H
2964063Q
2021021E
2964065S
2964070X
2964071Y
2964568R
2041804D
2964564M
2964066T
2964073A
2964566P
2021125N
2964057J
2964358X
2964560H
2964357W
2964567Q
2964161S
2052346K
2041827C
2043007G
2964359Y

rev. 1.0 - 12/2009

Remarks

1
2
2
1
1
2
2
1
1
1
6
10
2
1
1
1
2
6
7
2
1
6
2
1
1
1
7
4
1
1
1
1
1
4
2
2
1
4
1
2
2
2
2
2
1
1
1
1
2
4
4
2
1

9-23

075.1

Service Manual

Number

Description

Part number Quantity

53
54
55
56
57
58
59
60
61
62
63
64
65
66

Hex. head screw M4 x 8


Washer 12 x 6.2 x 0.8 mm
Sleeve
Pin
Pressure spring 1 mm
Wiring plate
Round head screw M3 x 6
Axle
Guide plate
Insert table
Countersunk head screw M3 x 8
Axle for fingers
Spring clip 6 - 8 mm
Guide plate bracket

2053880H
2040140V
2964370K
2964371L
2031114T
2989158F
2454302P
2964169A
2825203U
2994300M
2050414X
2964059L
2052446P
2825218K

9-24

Remarks

8
1
2
1
10
1
2
1
1
1
6
1
3
2

rev. 1.0 - 12/2009

Service Manual

075.1

Intentionally blank

rev. 1.0 - 12/2009

9-25

LH

7
8

9-26
40 41 42 (34)

28 27 26 25 24

43 44 45 46 47 48 49

10 11 12 13 14 15 16

23 22 21 20 19 18 17

RH

9.10

39 38 37 36 35 34 33 32 31 30 29

075.1
Service Manual

Insert and eject mechanism

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49

Inside frame (upper unit) LH


Loc frame
Hex. head screw M4x8
Round head screw M4x16
Connecting plate loc
Rubber damping ring
Pressure spring
Washer 14 x 8.2 x 0.8 mm
Solenoid
Washer 9 x 4.3 x 0.8 mm
Round head screw M4x5
Bracket for photocell
Pan head tapping screw
Led (including holder)
Cross connecting plate
Inside frame (upper unit) RH
Spring clip 7 - 9 mm
Timing belt
Pulley 21T
Cyl. pin 2.5 x 16
Washer 16 x 10.2 x 0.8 mm
Conductive bearing 10 mm
Drive axle
Round head screw M4x8
Washer 12 x 4.3 x 1 mm
Paper guide
Transportation roller 30 mm
Pressure spring 0.85 mm
Spring clip 10 - 14 mm
Tension spring
Bearing plate
Spacer 15 x 10.4 x 5 mm
Spacer 15 x 10.4 x 7.5 mm
Gear 15T
Gear 14T
Axle
Gear 20T
Bearing plate
Spacer 17 x 10.2 x 2 mm
Bearing plate
Spacer 15 x 10.4 x 10 mm
Gear 15T
Rod
Transportation axle
Bearing plate
Clamping ring 3 mm
Draw bar
Spacer 15 x 10.4 x 3 mm
Transportation roller 30 mm

2825322T
2994383Y
2053880H
2053871Y
2957260D
2040027C
2031195C
2040141W
2121287Y
2453745J
2454311Y
2964731L
2453855Y
2042452D
2964729J
2825331C
2052442K
2041537A
2041870X
2052346K
2040143Y
2042426B
2964723C
2053868V
2453743G
2964730K
2964364D
2431112H
2052483C
2033562T
2964720Z
2040837W
2040828M
2240944R
2964179L
2964717W
2240258B
2964719Y
2041094P
2964721A
2040830P
2732942P
2432681S
2964718X
2964722B
2052463G
2432679Q
2040858T
2041827C

rev. 1.0 - 12/2009

Remarks

1
2
11
4
2
1
1
2
1
3
6
1
1
1
1
1
1
1
1
6
9
10
1
4
2
2
2
3
4
2
1
3
2
2
1
1
1
1
2
1
2
1
1
1
1
4
1
3
2

9-27

075.1

9.11

9-28

Service Manual

Moistening unit

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

Bracket
Bearing 10mm
Pressure spring 0.85mm
Axle
Cyl. pin 2,5x16
Spring clip 10-14mm
Spring lever
Tension spring
Washer 12x4,3x1mm
Round head screw M4x16
Nut m4
Nut M4 (self-locking)
Buffer assy.
Lock brush holder
Brush holder
Spring
Not used
Grommet
Brush
Retaining spring
Round head screw m4x6mm
Round head screw M4x8
Hex. head screw M4x8
Round head screw m4x8
Countersunk head screw m4x10
Mounting bracket
Solenoid
Transportation roller 38mm
Cross bar

2964734P
2042426B
2431112H
2825266K
2052346K
2052483C
2232874K
2456404D
2453743G
2053871Y
2451902P
2053621N
2833497J
2045517W
2042994T
2041893W

1
2
2
1
2
1
1
1
2
1
1
1
1
1
1
1

2120474B
2720005N
2031187U
2454312Z
2053868V
2053880H
2453868M
2053875C
2969319Q
2121287Y
2042977A
2964727G

3
3
3
2
2
12
1
2
1
1
2
1

rev. 1.0 - 12/2009

Remarks

9-29

9-30

LH

25 24 23

26 27 28

40

29 30 31 32 33 34 35 36 37 38 39

41

22

21

20

14

13

12

11

10

RH

15 16 17 18 19

9.12

42

43

44

075.1
Service Manual

Envelope closing mechanism

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44

Round head screw M4x5


Bracket photocells divert
Sensor (incl. holder)
Solenoid
Mounting frame
Washer 9 x 4.3 x 0.8 mm
Lever
Washer 12 x 6.2 x 0.8 mm
Brake plate assy.
Transportation roller (assy.)
Spring clip 6 - 8 mm
Hinge bracket
Hex. head screw M4x8
Inside frame (upper unit) RH
Cyl. pin 12 x 16
Gear 15T
Pulley axle
Pulley/gear 15T
Timing belt
Round head screw M4x8
Protective plate loc
Loc frame
Cross bar
Inside frame (upper unit) LH
Grommet
Spacer 15 x 10.4 x 3 mm
Spacer 15 x 10.4 x 10 mm
Pan head tapping screw
Transportation axle
Bracket photocell - exit
Led (incl. holder)
Conductive bearing 10 mm
Pressure spring 0.7 mm
Spring clip 10 - 14 mm
Transportation roller 38 mm
Refer to 15
Transportation roller 30 mm
Ejection axle
Washer 16 x 10.2 x 0.8 mm
Nut M4
Clamping ring 3 mm
Draw bar
Pressure spring

2454311Y
2994265A
2042453E
2121287Y
2809025R
2453745J
2964703G
2040140V
2994309W
2841704H
2052446P
2964702F
2053880H
2989162K
2052346K
2045413N
2043353S
2043352R
2041537A
2453868M
2994073A
2994383X
2964727G
2989163L
2989275C
2040858T
2040830P
2453855Y
2232600Z
2825339L
2042452D
2042426B
2031111Q
2052483C
2042977A

3
1
1
1
1
4
1
8
1
2
4
1
15
1
5
1
1
1
1
2
1
2
1
1
1
1
4
1
1
1
1
4
2
4
2

2041827C
2964724D
2040143Y
2451902P
2052463G
2809028U
2031195C
2040141W

2
1
3
2
4
1
1
2

Washer

rev. 1.0 - 12/2009

14 x 8.2 x 0.8 mm

Remarks

9-31

075.1

Main drive mechanism

RH

27 26 25 24 23 22 21 20 19 18

8 9

10

17 16 15

14

11 12 13

9.13

Service Manual

9-32

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

Mounting bracket for spring


Hex. head screw M4x8
Fixing plate
Washer 14 x 8.2 x 0.8 mm
Axle for tensioner roller
Cyl. pin 2.5 x 16
Tensioner roller
Pulley 20T assy. (timing belt)
Timing belt
Spring clip 7 - 9 mm
Cyl. pin 2.5 x 20
Drive belt PJ
Main pulley
Tensioner roller
Pulley 50 Hz
Pulley 60 Hz
Set screw M4x8
Belt tensioner
Spring clip 9 - 12 mm
Washer 16 x 10.2 x 0.8 mm
Gear 30T
Spacer 15 x 10.4 x 7.5 mm
Hex. head screw M4x12
Spacer 9 x 4.1 x 2.5 mm
Gear 24T
Timing belt
Motor 220-240V/50Hz
Motor 100-115V/50-60Hz
Tensioner roller

2989116M
2053880H
2951307C
2040141W
2951310F
2052346K
2964368H
2042246P
2041621N
2052442K
2964193A
2964155L
2964369J
2964167Y
2989404M
2989405N
2082806P
2964166X
2052455Y
2040143Y
2964674B
2040828M
2453882B
2430851L
2930525E
2951316M
2989406P
2989407Q
2951319Q

rev. 1.0 - 12/2009

Remarks

3
8
2
2
2
5
1
4
1
2
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
1
1
1

9-33

075.1

Feeder/Folder driving mechanism

RH

21 20 19 18 17 16 15 14 13 12 11 10

9.14

Service Manual

9-34

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

Cyl. pin 2.5 x 20


Disc for pulley
Pulley 28T
Spring clip 8 - 11 mm
Timing belt
Spring clip 10 - 14 mm
Tensioner roller
Washer 14 x 8.2 x 0.8 mm
Pulley 36T
Spring clip 6 - 8 mm
Spacer 15 x 10.4 x 25 mm
Clutch CW 8 mm
Gear 24T
Hex. head screw M4x8
Blocking bracket
Gear 20T
Round head screw M4x8
Blocking bracket
Belt tensioner
Hex. head screw m4x12
Washer 12x4,3x1mm

2964193A
2964356V
2825516V
2052454X
2964662P
2052483C
2964194B
2040141W
2964656H
2052446P
2040825J
2121666T
2930525E
2053880H
2235615Q
2964199G
2053868V
2964198F
2825337J
2453882B
2453743G

rev. 1.0 - 12/2009

Remarks

2
2
2
1
1
2
1
1
1
1
1
2
1
3
1
1
1
1
1
2
2

9-35

075.1

22

21

20

19

17

18

16

15

23

25 24

9 10 11 12

RH

32 31 30 29 28 27 26

14

Envelope track driving mechanism 1/2


13

9.15

Service Manual

9-36

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

Belt tensioner
Hex. head screw M4x8
Tension pin 2.5 x 16
Spacer 15 x 10.4 x 5 mm
Gear 28T
Gear 18T
Spring clip 9 - 12 mm
Washer 16 x 10.2 x 0.8 mm
Cyl. pin 2.5 x 20
Disc for pulley
Timing belt
Pulley 36T
Spring clip 10 - 14 mm
Mounting plate
Round head screw M4x6
Round head screw M3x8
Washer 7 x 3.2 x 0.5 mm
Adj. plate
Pulse disc sensor (assy.)
Pulse disc
Clamping disc
Washer 20 x 6.2 x 2 mm
Countersunk head screw M4x8
Pulley 30T
Tensioner roller
Pulley 20T
Gear 35T
Spacer 15 x 10.4 x 10 mm
Gear 18T
Accessory connector (incl. wiring)
Round head screw M4x8
Locking plate

2964676D
2053880H
2053322B
2040837W
2240261E
2240936H
2052455Y
2040143Y
2964193A
2964356V
2964355U
2964160R
2052483C
2964180M
2053866T
2053865S
2453739C
2964181N
2821622P
2241281S
2433046X
2430790X
2454212V
2964164V
2964194B
2964157N
2246952Z
2040830P
2964351Q
2825940M
2053868V
2964165W

1
2
4
4
2
2
3
4
4
3
1
1
4
1
1
3
3
1
1
1
1
1
1
2
2
1
1
1
2
1
2
2

Remarks

See note

Note
In case the optional High Capacity Vertical Stacker (HCVS-1) is part of the system.

rev. 1.0 - 12/2009

9-37

RH

9-38

30 29 28

36 35 34 33 (23)32 31

27 26 25 24

37 38 39 40

19 18 17 16 15

9 10 11 12 13 14

9.16

23 (8) 22 21 20

(19)

075.1
Service Manual

Envelope track driving mechanism 2/2

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

Cyl. pin 2.5 x 12


Slip clutch CCW 8mm
Timing belt
Pulley 15T (assy.)
Conductive bearing 10 mm
Countersunk head screw M4x10
Spacer 17 x 10.2 x 2 mm
Gear 35T
Catch disc
Clutch CW 8 mm
Cyl. pin 2.5 x 16
Gear 18T
Washer 14 x 8.2 x 0.8 mm
Spring clip 6 - 8 mm
Round head screw M4x8
Support plate
Spring clip 10 - 14 mm
Gear 28T
Gear 35T
Freewheel clutch assy.
Spring clip 9 - 12 mm
Gear 28T
Gear 14T
Nut
Washer 17 x 8.4 x 1.6 mm
Spring holder disc
Pressure spring 1.5 mm
Spring clip 8 - 11 mm
Gear 18T
Gear 15T
Gear 21T
Gear 15T (assy.)
Spacer 15 x 10.4 x 3 mm
Brake rod
Spacer 15 x 10.4 x 5 mm
Spacer 12 x 8.4 x 5 mm
Cyl. pin 12 x 16
Pulley 13T
Intermediate axle
Tension pin 2.5 x 20

2052347L
2957127Q
2951316M
2930554K
2042426B
2454213W
2041094P
2246958F
2235506B
2121666T
2052346K
2964174F
2040141W
2052446P
2053868V
2964185S
2052483C
2241140V
2246952Z
2964360Z
2052455Y
2240261E
2964179L
2451920H
2453738B
2246943Q
2031173E
2052454X
2240936H
2045413N
2241650B
2746942X
2040858T
2964184R
2040837W
2040964D
2053322B
2964177J
2964176H
2053324D

rev. 1.0 - 12/2009

Remarks

1
1
1
1
9
2
1
2
1
1
3
1
3
1
1
1
5
1
2
1
2
1
2
2
2
2
1
2
1
1
1
1
2
1
1
1
1
1
1
2

9-39

9-40

45 44 43 42 41 40

52

53

29

30

31

32

33

34

35

19

54

55

16

15

14

13

18

39 38 37

9 10 11 12

28 27 26 25 24 61 23 22 21 20

14

17

36

56

57

14

9.17

46 47 48 49 50 51

60 59 58

075.1
Service Manual

Document feeder unit (automatic)

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53

Upper separation roller


Tension pin 2.5 x 12
Pulley
Spring clip 7 - 9 mm
Not used
Transportation roller 30 mm
Transportation axle
Not used
Transportation axle (separation)
Pressure spring
Washer 14 x 8.2 x 0.8 mm
Bearing bush
Rubber paper puller
Paper puller axle assy.
Mounting strip
Upper plate feeder
Bottom plate assy. (daily mail feeder)
Frame plate feeder
Pressure spring
Round head screw M4x30
Nut M4 (self-locking)
Spacer
Round head screw M4x8
Conductive bearing 8 mm
Drive axle
Separation axle assy. (daily mail)
Cyl. pin 2.5 x 16
Transportation roller
Fixing strip
Fixing strip
Sleeve
Slide
Washer 12 x 4.3 x 1 mm
Nut M4
Wire spring
Round head screw M3x4
Drive axle extension
Hinge arm
Curved spring assy.
Spring lever
Cyl. pin 2 x 16
Gear 48T
Pulley 44T
Tensioner roller
Belt tensioner
Gear 64T (assy.)
Support axle extension
Tension pin 2.5 x 10
Fibre washer 10 x 5.2 x 1 mm
Bearing bush
Spring clip 5 - 7 mm
Led (including holder)
Bracket for photocell

2951167G
2053320Z
2951142F
2052442K

1
1
1
8

2042851U
2042853W

2
1

2951139C
2031114T
2040141W
2989311Q
2040016R
2042740D
2989321A
2989304H
2989326F
2989305J
2033520Z
2454319G
2053621N
2951337J
2053868V
2042425A
2964216Z
2042311G
2052346K
2951312H
2951182X
2989318X
2041157E
2951178T
2453743G
2451902P
2951179U
2454300M
2964220D
2989312R
2042880Z
2989309N
2052369J
2951132V
2951151Q
2951159Y
2989322B
2951170K
2951109W
2053319Y
2040107L
2041332M
2052466K
2042452D
2989310P

1
1
10
1
2
1
1
1
1
2
2
1
1
1
17
2
1
1
2
2
1
1
1
1
6
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1

rev. 1.0 - 12/2009

Remarks

Incl. item 13

9-41

075.1

Service Manual

Number

Description

Part number Quantity

54
55
56
57
58
59
60
61

Pan head tapping screw


Cork strip
Sensor (including holder)
DFC
Bottom plate assy.
Separation roller (lower)
Separation axle assy. (auto)
Blocking bracket

2453855Y
2951126P
2042453E
2790171C
2989308M
2951168H
2042263G
2989557W

9-42

Remarks

2
2
1
1
1
1
1
1

rev. 1.0 - 12/2009

Service Manual

075.1

Intentionally blank

rev. 1.0 - 12/2009

9-43

075.1

9.18

9-44

Service Manual

Document feeder unit - special 1/2

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43

Torsion spring
Transportation roller special
Pulley
Hub
Paper puller axle assy.
Tension roller arm
Spring clip 8-11mm
Tensioner roller
Drive axle extension
Gear 48t
Drive axle
Cyl. pin
Bearing 8mm
Separation axle extension
Transportation axle
Transportation roller
Pressure spring
Bearing bush
Coupling sleeve
Spacer 12x8,3x3mm
Spring clip 5-7mm
Fibre washer 10x5,2x1mm
Round head screw M4x16
Support axle extension
Cyl. pin 2,5x16
Pan head screw M4x10 (Torx)
Gear 54T/16T
Gear 16t
Suspension bracket
Bearing 6mm
Pulley 20t
Spring clip 6-8mm
Spring clip 7-9mm
Washer 12x6,2x0,8mm
Washer 14x8,2x0,8mm
Rubber paper puller
Tension pin 2,5x12
Gear 64t assy.
Spring clip 4-5mm
Cyl. pin 2,5x10mm
Transportation roller 30mm
Separation axle assy. (special)
Transportation roller assy.

2951250T
2043205N
2951251U
2951252V
2042740D
2989322B
2052454X
2045502F
2045348V
2951132V
2964224H
2052369J
2042425A
2951109W
2042853W
2042851U
2033520Z
2041332M
2951212D
2041050T
2052466K
2040107L
2053871Y
2951220M
2052346K
2045491U
2741288H
2964227L
2951232Z
2042424Z
2951142F
2052446P
2052442K
2040140V
2040141W
2040016R
2053320Z
2951170K
2052447Q
2052370K
2951312H
2042312H
2043203L

rev. 1.0 - 12/2009

1
1
1
1
1
1
2
1
1
1
1
2
2
1
1
2
2
2
2
1
2
3
2
1
2
2
2
2
2
2
1
2
6
2
8
2
4
1
2
2
2
1
1

Remarks

Incl. item 36

9-45

075.1

9.19

9-46

Service Manual

Document feeder unit - special 2/2

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

Nylon bearing
Round head screw m3x8
Pan head tapping screw 2.9x6.5
Frame plate feeder LH
Support bracket (lower)
Bracket for photocell
Bottom plate feeder
Mounting strip
Round head screw m3x4
Spacer
Paint piercing washer 8x4,3x0,5
Stop plate
Leaf spring
Round head screw M4x16
Clamping plate
Countersunk head screw M4x10 (Torx)
Round head screw m4x25mm
Nut M4 (self-locking)
Nut m4
Torx screw m4x8
Support bracket (upper)
Round head screw m3x6
Frame plate feeder RH
Pan head screw M4x10 (Torx)
Sensor (including holder)
DFC
Led (including holder)
Upper plate feeder
Mounting plate

2040966F
2453865J
2053855G
2045482K
2951231Y
2989310P
2045487Q
2989321A
2454300M
2951337J
2052431Y
2045490T
2951207Y
2053871Y
2951246P
2045504H
2454318F
2053621N
2451902P
2053850B
2951214F
2454302P
2045481J
2045491U
2042453E
2790171C
2042452D
2045484M
2951234B

rev. 1.0 - 12/2009

Remarks

2
1
2
1
1
1
1
1
2
1
1
1
1
2
1
3
1
1
1
12
1
1
1
5
1
1
1
1
1

9-47

075.1

9.20

Service Manual

Document feeder trays

1
2
3

RH
22
21
20

4
5
6

LH

7
8

19
18
17

16
15

9
10
11
12
13
14

9-48

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

16
17
18
19
20
21
22

Hex. head screw M4x16


Guide roller (assy.)
Side guide RH
Side guide LH
Gear
Washer 14 x 6.5 x 0.8 mm
Pressure spring
Spacer 8 x 4.3 x 3 mm
Carrier
Carrier
Washer 15 5.3 x 2 mm
Finger knob
Nut M4
Knurled nut
Self-locking nut
Short feeder tray - 1 piece
Short feeder tray - set of 2 pieces
Short feeder tray - 1 piece - special
Locking lever
Roller
Adj. rod
Lever
Hinge
Hinged side guide
Countersunk head screw M4x6

2451240Z
2042709W
2825470X
2825471Y
2951014X
2430247G
2033520Z
2041132D
2042737A
2042738B
2453750P
2741497A
2451902P
2042749N
2053621N
2042651L
2042727Q
2100980V
2100956V
2951019C
2951022F
2951020D
2951025J
2825472Z
2454211U

1
2
1
1
2
1
2

Document feeder tray complete


Document feeder tray complete

2825341N
2825340M

1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
-

Remarks
Optional

See note
See note
See note
See note

Optional
Optional
Optional

See note

Automatic
Special

Note
These parts are part of the special feeder.

rev. 1.0 - 12/2009

9-49

075.1

9.21

9-50

Service Manual

Vertical track (base)

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46

Frame axle
Drive axle
Drive axle assy.
Bearing 10mm
Center cover plate
Guide plate
Cover plate
Blocking bracket
Countersunk tapping screw
Round head screw M4 x 8
Adjustment plate
Hinge pin
Hex. head screw M4x8
Frame axle
Lower cover plate
Round head screw M4x6
Microswitch (including lever)
Mounting plate
Round head screw M4x8
Nut M3
Tension spring
Disc
Mounting bracket for spring
Tension spring
Lever
Tension pin 2,5x12
Tension spring
Washer 16x10,2x0,8mm
Nylon bearing
Spring clip 9-12mm
Washer 7x3,2x0,5mm
Timing belt
Pulley 44t
Clutch ccw 8mm
Cyl. pin 2,5x16
Bearing 8mm
Spring clip 6-8mm
Spacer 12x8,4x5mm
Lock axle
Round head screw m3x16
Transport roller 30x10x11
Feeder frame assy. LH
Led (including holder)
Feeder frame assy. RH
Mounting plate
Transportation roller

2951303Y
2964653E
2951314K
2042426B
2964625A
2825383G
2951327Y
2964677E
2453856Z
2054313J
2825325W
2989323C
2053880H
2951324V
2964615Q
2053866T
2989056Z
2989187L
2053868V
2451901N
2455404M
2930539U
2989116M
2951150P
2951021E
2053320Z
2951328Z
2040143Y
2041271Y
2052455Y
2453739C
2041574P
2951308D
2930536R
2052346K
2042425A
2052446P
2040964D
2825324V
2053867U
2995420D
2825394T
2042452D
2825395U
2965331L
2995419C

rev. 1.0 - 12/2009

Remarks

1
1
2
1
1
1
2
3
1
2
2
6
15
3
1
11
1
1
11
2
3
3
3
3
3
3
3
3
6
6
5
3
3
3
6
2
3
6
1
3
2
1
1
1
1
4

9-51

075.1

9.22

9-52

Service Manual

Vertical track (loc)

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2

Frame vertical transport


Guide plate

2825388M
2825391Q

1
1

3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

Mounting bracket
Guide plate (lower)
Positioning plate
Nut m4
Pan head tapping screw
Round head screw m4x8
Pressure roller axle
Tension spring
Locking plate
Guide axle
Paper guide
Hinge pin
Round head screw m4x16
Pressure spring
Transportation roller
Bearing 6mm
Washer 12x6,2x0,8mm
Spring clip 6-8mm
Hex. head screw M4x8
Guide plate (upper)
Locking bracket
Locking bracket
Sensor (including holder)
Reading head assy.

2964143Y
2825384H
2989157E
2451902P
2453853W
2453868M
2042852V
2033561S
2825263G
2964201J
2995002T
2964112R
2453871Q
2033520Z
2042851U
2042424Z
2040140V
2052446P
2053880H
2825382F
2825427C
2825431G
2042453E
2989434T

1
1
1
1
1
12
3
2
1
2
4
2
2
6
6
6
6
6
2
1
1
1
1
1

24
25

rev. 1.0 - 12/2009

Remarks
without
reading
option
installed

Francotyp

9-53

9-54

LH

41 40 39 38 37 36 35 34 33 32 31

42 43

46

48

49

44

8
9

30 29 28 27

50 51 52 53 54 55

26 25 24 23 22 21 20

19 18 17 16 15 14 13 12 11

10

RH

9.23

47

45

075.1
Service Manual

Collating unit (upper)

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51

Inside frame LH
Tension spring
Nut M4
Hinged guide plate
Sensor (including holder)
Pan head tapping screw
Leaf spring
Frame
Hex. head screw M4x8
Inside frame RH
Roller
Cyl. pin 2 x 16
Washer 12 x 6.2 x 0.8 mm
Conductive bearing 6 mm
Frame (collator area)
Axle
Tensioner
Pressure spring
Guide plate
Spring clip 6 - 8 mm
Pressure roller assy. (incl. O-ring)
Hinge axle
Pressure spring
Axle
Belt tensioner
Set screw M4x4
Nylon bearing
Spring clip 4 - 5 mm
Round head screw M3x8
Collating belt set (3 pcs.)
Drive axle (collator area)
Conductive bearing 8 mm
Washer 16 x 10.2 x 0.8 mm
Set screw M4x4
Roller
Bushing 15 x 10.2 x 5.5 mm
Frame collator motor
Motor 24V
Pulse disc sensor (assy.)
Set screw M3x4
Pulse disc
Round head screw M4x6
Round head screw M4x16
Spring clip 8 - 11
Clamping ring
Round head screw M4x8
Pan head tapping screw
Mounting bracket
Led (including holder)
Pressure roller 20 mm
Axle 6 mm

2825315L
2033539U
2451902P
2964134P
2042453E
2453855Y
2989423G
2964304R
2053880H
2825316M
2989401J
2052369J
2040140V
2042424Z
2964302P
2964306T
2964300M
2964332V
2964301N
2052446P
2952011L
2964308V
2033543Y
2964309W
2952015Q
2082801J
2041107C
2052447Q
2053865S
2952007G
2989422F
2042425A
2040143Y
2082801J
2989400H
2753751Q
2989421E
2989409S
2975505J
2082833S
2964343G
2053866T
2053871Y
2052454X
2052486F
2053868V
2453853W
2964312Z
2042452D
2951408H
2989424H

rev. 1.0 - 12/2009

Remarks

1
2
1
1
2
2
1
1
7
1
6
6
10
2
1
1
1
2
1
6
3
4
2
1
2
2
4
8
3
1
1
1
3
1
3
1
1
1
1
5
1
2
4
1
1
3
2
1
2
2
1

9-55

075.1

Service Manual

Number

Description

Part number Quantity

52
53
54
55

Cyl. pin 2.5 x 16


Transportation roller 30 mm
Transportation axle (assy.)
Paper guide strip

2052346K
2041827C
2964655G
2964133N

9-56

Remarks

2
2
1
1

rev. 1.0 - 12/2009

Service Manual

075.1

Intentionally blank

rev. 1.0 - 12/2009

9-57

075.1

9.24

Service Manual

Collating unit (lower) and power supply

1
2
3
5
6

45 46 47 48 49 50 51

7
8
9
10
11
12
13
14

44
43
42
41
40

39
38
37
36
35
34

15
16
17

33
32
31
30

RH
18
19
20
21

LH
29
28

9-58

27
26

25 24 23 22

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47

Collating plate
Round head screw M4x8
Collator stop axle
Paper stop
Locking plate rack
Gear rack
Pulse disc sensor
Screw M4x8
Bracket (for pulse disc sensor)
Cover plate RH
Screw M2x4
Gear
Bottom frame collator assy.
Spring
Microswitch (incl. lever)
Screening plate
Round head screw M3x12
Countersunk head screw M4x10
Isolating plate
Printed board holder
Motor relay board 230V
Motor relay board 115V
Guide plate
Spring clip 6 - 8 mm
Tension spring
Hinge axle
Fuse 2.5A/230V slow blow
Fuse 5A/125V
Power inlet
Foot assy.
Hex. head screw M4x8
Power supply
Power supply frame
Capacitor 5 mF (230 V)
Capacitor 20 mF (115 V)
Capacitor 5 mF (230 V)
Capacitor 20 mF (115 V)
Washer 9 x 4.3 x 0.8 mm
Lock washer 5/32
Motor collator stop 24v
Guide roller
Grommet
Cover plate LH
Hinge axle
Spring clip 10 - 14 mm
Clamping ring 4 mm
Rod
Counter roller
Nut M4
Washer 9 x 4.3 x 0.8 mm
Axle

2994209S
2053868V
2994230P
2952141W
2994241A
2994231Q
2975505J
2053868V
2994234T
2964328R
2994237W
2994238X
2994229N
2994236V
2989056Z
2964337A
2454305S
2453875U
2989004V
2041075U
2975500D
2975540V
2989201A
2052446P
2033536R
2989204D
2975543Y
2121549W
2989005W
2994108M
2053880H
2989002T
2989203C
2989006X
2121281S
2989006X
2121281S
2453702P
2052431Y
2994232R
2964319G
2120983G
2964327Q
2964322K
2052483C
2052462F
2964325N
2952111Q
2451902P
2453745J
2952112R

rev. 1.0 - 12/2009

Remarks

1
16
2
2
1
1
2
1
1
1
2
1
1
2
1
1
2
1
1
4
1
1
2
6
2
1
1
1
1
2
2
1
1
1
1
1
1
2
2
1
2
1
1
1
4
2
1
18
4
4
2

9-59

075.1

Service Manual

Number

Description

Part number Quantity

48
49
50
51

Tilting plate
Tension spring
Roller
Transportation axle

2952114T
2456404D
2952113S
2964324M

9-60

Remarks

2
1
1
6

rev. 1.0 - 12/2009

Service Manual

075.1

Intentionally blank

rev. 1.0 - 12/2009

9-61

9-62

LH

(18) (21)(18)

26

22 21 20 19 18 17 16 15 14

23 24 25

(10)

27

28

29

30

31

13 12 11 10

RH

9.25

32

33

075.1
Service Manual

Folder unit (base)

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33

Bearing locking plate


Washer 15 x 5.3 x 2 mm
Countersunk head screw M4x10
Conductive bearing 6 mm
Washer 12 x 6.2 x 0.8 mm
Spring clip 6 - 8 mm
Hex. head screw M4x8
Washer 20 x 6.2 x 2 mm
Bearing locking plate
Upper input roller (assy.)
Lower input roller (assy.)
Screening plate (assy.)
Wiring guide
Round head screw M3x8
Countersunk head screw M3x10
Round head screw M3x4
Cyl. pin 2.5 x 16
Gear 24T
Spring clip 10 - 14 mm
Spacer 15 x 10.4 x 3 mm
Gear 35T
Washer 16 x 10.2 x 0.8 mm
Flap actuator
Cyl. pin 2 x 12
Round head screw M4x16
Sleeve
Fixing screw M3x6
Flap assy. incl. torsion spring
Torsion spring
Flap assy. (incl. axle)
Synthetic leaf spring
Guide bracket
Guide strip

2930613W
2453750P
2053875C
2042424Z
2040140V
2052446P
2053880H
2430790X
2930612V
2825300V
2825313J
2964264Z
2964258T
2053865S
2053874B
2454300M
2052346K
2930525E
2052483C
2040858T
2246958F
2040143Y
2953084D
2953085E
2053871Y
2040027C
2953083C
2042771L
2033538T
2042750P
2930654P
2953073S
2930653N

rev. 1.0 - 12/2009

Remarks

2
4
6
4
4
4
5
2
2
3
1
1
1
4
2
2
3
3
5
4
2
2
2
2
2
2
4
2
2
2
4
1
1

9-63

075.1

9.26

Service Manual

Folder unit (loc) 1/4


1

9 10 11

RH
12 13 14 15

21 20
19

LH

18
17
16

22 23 24

RH
25 26 27 28 29 30 31

LH
33
32

9-64

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33

Round head screw M4x16


Leaf spring
Round head screw M4x8
Locking plate
Bracket
Spring clip 10 - 14 mm
Conductive bearing 10 mm
Tension pin 2.5 x 20
Curve axle
Mounting bracket
Curve disc RH
Guide plate (assy.) (first fold table)
Countersunk head screw M3x10
Axle for fold plate
Hinge plate RH
Fold plate
Hinge strip (paper guide) LH
Hinge plate LH
Washer 14 x 8.2 x 0.8 mm
Spring clip 7 - 9 mm
Curve disc LH
Nut M4
Washer 12 x 4.3 x 1 mm
Mounting bracket
Guide plate (second fold table)
Paper guide
Pressure spring
Stop nut
Set screw M4x4
Hinge strip (paper guide) RH
Bushing
Fold plate
Hinge strip (paper guide) LH

2053871Y
2953060D
2053868V
2953095Q
2953090K
2052483C
2042426B
2053324D
2953110F
2953056Z
2043362B
2953051U
2053874B
2953030X
2953011C
2964207Q
2953020M
2953010B
2040141W
2052442K
2043361A
2451902P
2453743G
2953059C
2953053W
2953026T
2031195C
2975335G
2082801J
2975273S
2975345S
2953016H
2975272R

rev. 1.0 - 12/2009

Remarks

4
2
2
1
2
4
4
4
2
1
2
1
14
2
2
1
2
2
4
4
2
2
2
1
1
1
2
2
3
1
2
1
1

9-65

075.1

Folder unit (loc) 2/4

LH

10

RH

9.27

Service Manual

9-66

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10

Conductive bearing 8 mm
Spacer 12 x 8.3 x 3 mm
Washer 14 x 8.2 x 0.8 mm
Spring clip 7 - 9 mm
Gear 32T (incl. catch)
Clutch CCW 8 mm
Cyl. pin 2.5 x 12
Spacer 18 x 12.8 x 3 mm
Clutch CW (clockwise) 8 mm
Drive axle (fold)

2042425A
2041050T
2040141W
2052442K
2964219C
2121461E
2052347L
2040871G
2121463G
2930510P

rev. 1.0 - 12/2009

Remarks

2
1
6
4
2
1
2
2
1
1

9-67

075.1

Folder unit (loc) 3/4

25 24 23 22 21 20 19

26 27 28

18 17 16 15

LH

14 13 12 11 10

9.28

Service Manual

9-68

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28

Lever for flap actuator


Cyl. pin 2 x 32
Spring clip 8 - 11 mm
Washer 14 x 8.2 x 0.8 mm
Conductive bearing 8 mm
Inside frame (upper unit) LH
Bracket
Pulse disc sensor
Round head screw M4x5
Guide plate
Round head screw M4x6
Upper fold roller (assy.)
Fold roller (assy.)
Guide strip
Round head screw M3 x 8
Bearing locking plate
Washer 15 x 5.3 x 2 mm
Countersunk head screw M4x10
Torsion spring
Round head screw M4x16
Ball bearing
Positioning lever
Nut M4 (self-locking)
Washer 16 x 10.2 x 0.8 mm
Spring clip 9 - 12 mm
Brake disc
Cyl. pin 2.5 x 16
Conductive bearing 10 mm

2953031Y
2052308V
2052454X
2040141W
2042425A
2989163L
2975461N
2975505J
2454311Y
2964138T
2053866T
2825307C
2825300V
2953073S
2453865J
2930613W
2453750P
2053875C
2953070P
2053871Y
2031281S
2953068M
2053621N
2040143Y
2052455Y
2953066K
2052346K
2042426B

rev. 1.0 - 12/2009

Remarks

2
2
2
4
2
1
2
2
8
1
1
1
1
1
1
1
2
2
2
2
2
2
2
6
2
2
2
2

9-69

36 35 34 33 32

31 30 29 28

9-70
21 20

13 14 15 37

12

11

10

19

18

17

16

9.29

27 26 25 24 23 22

RH

075.1
Service Manual

Folder unit (loc) 4/4

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37

Inside frame (upper unit) RH


Washer 14 x 8.2 x 0.8 mm
Conductive bearing 8 mm
Countersunk head screw M4x10
Spring clip 8 - 11 mm
Belt tensioner
Round head screw M4x6
Tension axle
Spacer
Brush lever
Hex. head screw M4x8
Locking plate
Cyl. pin 2.5 x 12
Slip clutch CCW 8mm
Pulley 18T
Washer 14 x 6.5 x 0.8 mm
Tensioner roller
Timing belt
Pulley
Spring clip 10 - 14 mm
Gear 24T
Cyl. pin 2.5 x 16
Spacer 17 x 10.2 x 2 mm
Gear 35T
Spacer 15 x 10.4 x 3 mm
Washer 15 x 5.3 x 2 mm
Bearing locking plate
Pressure spring
Brake disc
Brake strip
Conductive bearing 10 mm
Round head screw M4x8
Guide strip
Fold roller (assy.)
Upper fold roller (assy.)
Guide plate
Spacer 12 x 8,3 x 7,5 mm

2989162K
2040141W
2042425A
2053875C
2052454X
2825334F
2053866T
2964669W
2041098T
2043021W
2053880H
2964165W
2052347L
2957127Q
2825332D
2430247G
2951319Q
2975255Y
2964160R
2052483C
2930525E
2052346K
2041094P
2246958F
2040858T
2453750P
2930613W
2953100V
2953094P
2953097S
2042426B
2053868V
2953073S
2825300V
2825307C
2964138T
2040859U

rev. 1.0 - 12/2009

Remarks

1
7
2
4
3
1
7
1
1
1
1
1
1
1
1
1
1
1
1
2
2
4
1
1
2
2
1
2
4
1
2
1
1
1
1
1
1

9-71

075.1

9
8
3

1 2

19 18 17

LH

16 15 14 13 12

11

Electrical components
10

9.30

Service Manual

9-72

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14

Color touch screen


Ejot screw 3x10
Display connector board
Grommet
Mounting bracket display
Round head screw M4x4
Spacer nut
Wiring display 075.1
Keyboard PCB
PCB holder
Communication board
Round head screw M4x35
Lock washer 5/32"
Main board 075.1
Pre-programmed main board 075.1
Spacer 8 x 4 x 25 mm
Dongle socket
Empty flex dongle
PCB holder
Pop rivet
ID tag

2994510F
2989182F
2994502X
2120480H
2994048Z
2454310X
2994074B
2989082B
2994508D
2041657A
2992000R
2454320H
2052431Y
2825900V
2825942P
2040883U
not applicable
2994506B
2930807Y
2994107L
2994504Z

15
16
17
18
19

rev. 1.0 - 12/2009

Remarks

1
4
1
1
1
2
4
1
1
2
1
1
1
1
1
1
5
1
1

9-73

075.1

9.31

9-74

Service Manual

High capacity feeder 1/4

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

Pulley assy. 25T (timing belt)


Spacer
Spring clip 6-8mm
Nut M6 (self-locking)
Washer 6,4 (B)
Spacer 12x8,4x5mm
Timing belt
Timing belt
Timing belt
Clutch ccw 8mm
Spring clip 8-11mm
Round head screw m4x8
Blocking bracket
Spring clip 7-9mm
Tensioner roller
Washer 14x8,2x0,8mm
Axle for tensioner roller
Fixing plate
Round head screw M4 x 8
Tensioner roller
Timing belt
Pulley 20T(timing belt)
Hex head screw M4x8
Washer
Cyl. pin 2,5x16
Pulley assy. 25T (RPM)
Hinge arm 1 assy.
Lever arm 2 assy.
Pulley assy. 25T
Hinge arm 2 assy.
Belt tensioner

2825033S
2040825J
2052446P
7175107
7180820
2040964D
2825051L
2825012V
2825096H
2930536R
2052454X
2453868M
2964677E
2052442K
2964368H
2040141W
2951310F
2951307C
2054313J
2964194B
2951316M
2241375Q
2453881A
2253757N
2052346K
2825031Q
2825026K
2825028M
2825021E
2825024H
2964166X

rev. 1.0 - 12/2009

Remarks

1
1
1
1
1
2
1
1
1
1
3
1
1
1
1
4
1
1
1
1
1
3
3
1
4
1
1
1
2
2
1

9-75

075.1

9.32

9-76

Service Manual

High capacity feeder 2/4

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
24
25
26
26
27
28
29
30
31
32
33
34
35

Spacer 10x5,3x10mm
Spring clip 8-11mm
Transportation plate
Tension spring
Cover plate HCF
Drive axle
Ball bearing
Transportation axle
Bearing 8mm
Cyl. pin 2,5x16
Locking plate
Ball bearing
Spring clip 10-14mm
Washer 12x6,2x0,8mm
Tension spring
Frame axle
Spring clip 5-7mm
Journal
Hex head screw M4x8
Round head screw m4x25mm
Nylon bearing
Nut M4 (self-locking)
Bar
Washer 14x8,2x0,8mm
Spring clip 6-8mm
Countersunk head screw m4x6
Axle HCF
Hinge axle
Round head screw m4x6mm
Transportation roller
Lower arm HCF
Frame assy. LH
HCF lever
Frame assy. RH
U-frame

2040951Q
2052454X
2825035U
2825068D
2825061W
2951304Z
2031290B
2825001J
2042425A
2052346K
2825049J
2964675C
2052483C
2040140V
2031154K
2951303Y
2052466K
2825007Q
2453881A
2454318F
2040966F
2053621N
2825004M
2040141W
2052446P
2454211U
2825082T
2825040Z
2454312Z
2995419C
2825088Z
2825080R
2825091C
2825081S
2825084V

rev. 1.0 - 12/2009

Remarks

1
7
1
2
1
1
1
1
3
4
2
2
2
2
1
2
2
2
11
1
3
1
1
6
4
4
1
2
5
4
1
1
1
1
2

9-77

075.1

9.33

9-78

Service Manual

High capacity feeder 3/4

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

Remarks

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

Paper pulley axle assy.


Tension pin 2,5x12
Cyl. pin
Drive axle extension
Gear 48t
Torx screw m4x8
Separation axle extension
Blocking bracket
Spring lever
Gear 20T
Transportation axle (separation)
Pressure spring d=1mm
Bearing bush
Rubber paper puller
Tension pin 2,5x10mm
Fibre washer 10x5,2x1mm
Spring clip 5-7mm
Separation roller (upper)
Pulley 20t
Bearing bush
Transportation axle
Spring clip 7-9mm
Hinge arm
Curved spring
Spacer 12x8,3x3mm
Bearing 8mm
Cyl. pin 2,5x10mm
Gear 16t
Drive axle
Washer 14x8,2x0,8mm
Cyl. pin 2,5x16
Transportation axle
Spring clip 6-8mm
Transportation roller
Bearing 6mm
Pressure spring
Washer 12x6,2x0,8mm
Gear 64t assy.
Separation axle assy.
Transportation roller

2042740D
2053320Z
2052369J
2825045E
2951132V
2053850B
2825029N
2989557W
2989309N
2975281A
2951139C
2031114T
2989311Q
2040016R
2053319Y
2040107L
2052466K
2951167G
2951142F
2041332M
2825006P
2052442K
2989312R
2951106T
2041050T
2042425A
2052370K
2964227L
2964224H
2040141W
2052346K
2825005N
2052446P
2042851U
2042424Z
2033520Z
2040140V
2951170K
2042263G
2995419C

Incl. item 14

rev. 1.0 - 12/2009

1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
1
1
1
1
8
1
1
2
4
2
2
1
7
4
2
5
4
4
4
5
1
1
4

9-79

075.1

9.34

9-80

Service Manual

High capacity feeder 4/4

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Nylon bearing
Hex. head screw m4x12
Pan head tapping screw
Round head screw m3x8
Feeder plate assy. (rear)
Feeder plate assy. (lower)
Torx screw m4x8
Sleeve
Cover plate
Inside frame HCF LH
Mounting strip
Upper plate HCF
Mounting bracket
Cork strip
Nut m4
Slider
Wire spring
DFC
Sensor (including holder)
Led (including holder)
Inside frame HCF RH (assy.)
Fixing strip

2040966F
2453882B
2453855Y
2453865J
2825032R
2825057S
2053850B
2041157E
2825098K
2825008R
2825030P
2825010T
2825059U
2951126P
2451902P
2825063Y
2989313S
2790171C
2042453E
2042452D
2825074K
2989318X

2
1
2
2
1
1
17
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1

HCF tray complete

2825526F

rev. 1.0 - 12/2009

Remarks

9-81

075.1

9.35

9-82

Service Manual

High capacity feeder tray

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

Nut M4 (self-locking)
Nut m4
Washer 15x5,3x2mm
Knurled nut
Base plate assy. LH (side guide)
Side guide HCF
Rotation plate
Countersunk head screw m4x6
Hex. head screw m4x8
Gear 16T
Spring clip 5-7mm
Gear 70T
Countersunk head screw m4x8
Round head screw M4x8
Guide bush
Guide axle
Top plate assy.
Adjusting plate
Base plate assy. RH (side guide)

2053621N
2451902P
2453750P
2042749N
2825042B
2825521A
2825504H
2454211U
2964566P
2825519Y
2052466K
2825520Z
2454212V
2053868V
2825506K
2825502F
2825512R
2825523C
2825522B

rev. 1.0 - 12/2009

Remarks

1
1
1
1
1
2
1
3
2
1
1
1
9
4
2
1
1
1
1

9-83

075.1

9.36

9-84

Service Manual

Side exit 1/3

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28

Scotch tape
Self-sticking plug
Bracket
Round head screw m4x16
Connecting frame
Guide spring
Washer 9 x 4,3 x 0,8mm
Knurled nut
Nut m4
Transparent cover
Bearing bush
Pulley
Washer 12x4,3x1mm
Tension pin 2,5x16mm
Spacer 8x4,3x7,5mm
Drive axle
Bearing
Socket head screw m5x10
Gear 15T
Gear 18t
Washer 16x10,2x0,8mm
Countersunk head screw m4x10
Set screw M4x4
Spring clip 9-12mm
Nut m4 half d.
Bottom plate
Transportation table
Belt

2042451C
2959035C
2957389N
2453871Q
2957364M
2241008H
2453745J
2021125N
2451902P
2957393S
2957365N
2957374X
2453743G
2053322B
2040778K
2970101E
2042426B
2052850K
2240857A
2957376Z
2040143Y
2454213W
2082801J
2052455Y
2451919G
2957390P
2957366P
2957378B

rev. 1.0 - 12/2009

Remarks

1
2
1
2
1
1
9
1
11
1
1
2
1
1
2
1
2
2
1
1
2
1
2
1
2
1
1
2

9-85

075.1

9.37

9-86

Service Manual

Side exit 2/3

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity Remarks

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Torsion spring
Spring clip 4-5mm
Washer 9x3,2x0,8mm
Spacer 3,2x5x12,5mm
Spacer 11x9.2x2.5 mm
Washer 12x6,2x0,8mm
Round head screw m3x16
Guide bracket
Conical roller
Spring clip 8-11mm
Washer 16x10,2x0,8mm
Washer 14x8,2x0,8mm
Spring clip 10-14mm
Mounting plate
Washer 12x4,3x1mm
Spacer 8x4,2x8,5mm
Round head screw m4x16
Pulley
Guide plate
Arm for conical roller
Bracket
Pulley assy.

2033535Q
2052447Q
2453746K
2957372V
2430125E
2040140V
2454306T
2957385J
2957368R
2052454X
2040143Y
2040141W
2052483C
2957391Q
2453743G
2957363L
2454316D
2957362K
2957394T
2957370T
2957361J
2957377A

rev. 1.0 - 12/2009

2
2
2
2
2
2
3
1
2
4
4
4
2
1
4
4
4
6
1
2
1
2

9-87

075.1

9.38

9-88

Service Manual

Side exit 3/3

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12

Side guide
Nut M4 (self-locking)
Cover
Envelope support
Round head screw m4x16
Washer 9 x 4,3 x 0,8mm
Bottom plate
Washer 12x4,3x1mm
Crinkle washer
Absorber
Round head screw m4x6
Upper plate assy.

2957381E
2053621N
2957386K
2957382F
2453871Q
2453745J
2957383G
2453743G
2052484D
2241151G
2453866K
2957387L

rev. 1.0 - 12/2009

Remarks

1
1
1
1
4
4
1
1
1
6
1
1

9-89

075.1

9-90

Service Manual

rev. 1.0 - 12/2009

Service Manual
10

Appendix

10.1

075.1

Recommended spare parts

Page ref.

Legend
no.

Description

Part No

Stock per
number of
installed
machines
1

10

Remarks

50

page 9-6

12

Moistening cloth

2040306T

page 9-8

11

Stop button assy.

2825452D

12

Start button assy.

2825451C

13

Feed roller

2732731U

21

Pulley 15T (assy).

2930554K

20

Timing belt

2951316M

19

Slip clutch CCW 8 mm

2957127Q

15

Conductive bearing 10
mm

2042426B

16

O-ring (for jogger


roller)

2041876D

page 9-14

15

Separation roller
(assy.)

2994358X

page 9-16

Transportation roller
30 mm

2995420D

10

Sensor (including
holder)

2042453E

49

LED (including holder)

2042452D

50

Transportation roller
30 mm

2951312H

16

53

Conductive bearing 8
mm

2042425A

16

Rubber roller

2964190X

28

Pressure roller (assy.)

2964556D

page 9-12

page 9-20

rev. 1.0 - 12/2009

42 mm

10-1

075.1

Page ref.

Service Manual

Legend
no.

Description

Part No

Stock per
number of
installed
machines
1

page 9-22

10

50

Upper sealing roller


36 mm

2732648H

Lower sealing roller


(assy.)

2989433S

Conductive bearing 6
mm

2042424Z

16

33

Solenoid

2021021E

36

Finger

2964071Y

38

Leaf spring

2964564M

41

Hex. head screw


M4 x 8 (synthetic)

2964566P

43

Adjustable finger

2964057J

47

Transportation table
(assy)

2964567Q

Solenoid

2121287Y

18

Timing belt

2041537A

27

Transportation roller
30 mm

2964364D

42

Gear 15T

2732942P

28

Transportation roller
38 mm

2042977A

20

Retaining spring

2031187U

18

Grommet

2120474B

19

10-2

2989056Z

23

page 9-30

Microswitch (including
lever)

16

page 9-28

1
14

page 9-26

Remarks

Brush

2720005N

12

10

Transportation roller
(assy.)

2841704H

Remark: also
contains insert
rollers
2040945J

rev. 1.0 - 12/2009

Service Manual

Page ref.

Legend
no.

Description

Part No

075.1

Stock per
number of
installed
machines
1

page 9-32

10

Remarks

50

Timing belt

2041621N

12

Drive belt PJ

2964155L

11

Timing belt

2964355U

19

Pulse disc sensor


(assy.)

2821622P

20

Pulse disc

2241281S

25

Tensioner roller

2964194B

page 9-38

10

Clutch CW 8 mm

2121666T

page 9-40

Upper separation
roller*

2951167G

13

Rubber paper puller

2040016R

14

Paper puller axle assy.

2042740D

57

DFC

2790171C

59

Separation roller
(lower)*

2951168H

43

Transportation roller
assy.

2043203L

42

Separation axle assy.


(special)*

2042312H

37

Transportation roller
(special)*

2043205N

Document feeder tray


automatic

2825341N

Document feeder tray


special

2825340M

Clutch CCW 8 mm

2930536R

page 9-36

page 9-44

page 9-48

page 9-50

34

rev. 1.0 - 12/2009

10-3

075.1

Page ref.

Service Manual

Legend
no.

Description

Part No

Stock per
number of
installed
machines
1

10

Remarks

50

page 9-52

25

Reading head assy.

2989434T

page 9-54

21

Pressure roller assy.


(incl. O-ring)

2952011L

30

Collating belt set (3


pcs.)

2952007G

38

Motor 24V

2989409S

50

Pressure roller 20
mm

2951408H

14

Spring

2994236V

21

Motor relay board 230V

2975500D

Motor relay board 115V

2975540V

27

Power inlet

2989005W

36

Motor collator stop 24V

2994232R

10

Upper input roller


(assy.)

2825300V

11

Lower input roller


(assy.)

2825313J

Clutch CCW 8 mm

2121461E

Clutch CW (clockwise)
8 mm

2121463G

Lever for flap actuator

2953031Y

12

Upper fold roller assy

2825307C

13

Fold roller assy

2825300V

17

Tensioner roller

2951319Q

page 9-58

page 9-62

page 9-66

page 9-68

page 9-70

10-4

Remark: O ring
2040274K not
separately
fittable

rev. 1.0 - 12/2009

Service Manual

Page ref.

Legend
no.

Description

Part No

075.1

Stock per
number of
installed
machines
1

page 9-72

10

Remarks

50

Color touch screen

2994510F

Display connector
board

2994502X

Keyboard PCB

2994508D

14

Main board 075.1

2825900V

Pre-programmed main
board

2825942P

11

Communication board

2992000R

Timing belt

2825051L

Timing belt

2825012V

Timing belt

2825096H

Side guide HCF

2825521A

no ref.

Socket modem
(optional)*

2992002T

no ref.

Serial cable INF


interface

2994542P

no ref.

Phone cable external

2992005W

no ref.

Connection board
expanded (optional)*

2992003U

page 9-74

page 9-82

rev. 1.0 - 12/2009

10-5

075.1

10.2

Service Manual

Electrical diagrams

Board number

Board name

Refer to

2994502X

Display board

page 10-7

2994508D

Keyboard

page 10-9

2975540V (115 V) or
2975500D (230 V)

Motor relay board

page 10-10

2992003U (regular) or
2992001S (expanded) (optional)
2992002T (optional)

Connection board

page 10-12
page 10-13

2992000R (optional)

Communication board

page 10-14

2825900V or
2825942P

Main board
Pre-programmed main board

page 10-19
-

2994504Z

ID Tag

page 10-31

10-6

Modem board

rev. 1.0 - 12/2009

OLOR
STN
SPLAY

CCFL_GND

+3.3V

LCD_D0
LCD_D1
LCD_D2
LCD_D3
LCD_D4
LCD_D5
LCD_D6
LCD_D7

GND

LCD_FRM
LCD_CLK1
LCD_CLK2
LCD_DOFF

GND

2130-2161

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

J104

GND

J100

2
4
6
8
10
12
14
16
18
20

R113
10K

R104
10K

R114
56K

VDD_P
GND

VDD_A
DIM_CLK

R129
R139
R132
R131
R133

R119
R118
R125
R124
R127
R126
R121
R122
R123
R128

GND

C133
100nF

2
5
7
10
12
15

1Q
2Q
3Q
4Q
5Q
6Q

GND

3
4
6
11
13
14

GND

+3.3V

R134
10K

R150
10K

U104D
74HC14_3

3.3

U102
74HC174

1D
2D
3D
4D
5D
6D

CLK

CLR

+3.3V

U104C
74HC14_3

3.3

6
Q

Q
CL

CLK
4
1
U103A
74HC74

R141
10K

+3.3V

3.3

LCD_DD0
LCD_DD1
LCD_DD2
LCD_DD3

SPI_TOUCH_CS
SPI_ADC_DATA_IN

GND

TP101
GND

C113
470pF

C102 *
1.3pF

GND

+3.3V

GND

C122
100nF

8
7

15
14
13
12
16

J101

R116
150R

GND

+3.3V

CO102
100nF

REF

GND

CS
DIN
BUSY
DOUT
DCLK
AUX
BAT

BACK LIGHT

CO103
100nF

GND

C107
100nF

C106
100nF

C105
100nF

GND

R109
10K

R137
10K

GND

Audio driver

C110
100F

2 BP
3 + V-

4 1 SD V+

C118
470pF

GND

GND

GND

CO105
100F

C119
470pF

CO101_3
470pF

VCC_OUT

GND

GND

D100
BAT54S

+3.3V

CO101_2
100nF

GND

3
C120
470pF

GND

GND

R135
10K

13

11

12

GND

YB
XL
YT
XR
2130-2041

1
2
3
4

J103

LS100
20CS08KQ

D103
BAT54S

+3.3V

U103B
74HC74

CL

CLK

470pF

C121

GND

D102
BAT54S

+3.3V

U104F
74HC14_3
12 3.3 13

GND

D101
BAT54S

+3.3V

GND

U105
LM4871

L1
L2

VCC_OUT

R105
10K

Touchscreen controller
CO101_1
100F

CO104
100nF

GND

U101
MXB7846

X+

Y-

X-

Y+

R138
150R

DAC_SOUND

JAE/ IL-G-4P-S3T2

1
2
3
4

R110
150R

IRQ

R117
150R

11

C114
470pF

R120
10K

CCFL_GND

C123
100nF

Backligth
current
readback

R115
150R

Q100B
SI4946EY

SGE2671-1 1:50

C112
470pF

[2] SPI_ADC_DATA_OUT
[2] SPI_CLK

[2]

DAC_CONTRAST

LCD_CL1

C111
470pF

R136
56K

D104
BAT54S

LCD_ENABLE

LCD_CL1

LCD_FRM

GND

LCD_CL2

CO100_3
100nF

C100
470pF

C104
100nF

CCFL_GND

C103
100F

R108
10K

Q100A
SI4946EY
R107
10R

3
U104B
74HC14_3

U104A
74HC14_3
2 3.3 1

SPI_ADC_DATA_IN
SPI_MPLEX_CS2 [2]
SPI_ADC_DATA_OUT [2]
DAC_CONTRAST
DAC_SOUND

LCD_CL1
LCD_CL2
LCD_DD0
LCD_DD1
LCD_DD2
LCD_DD3
LCD_FRM
LCD_ENABLE
SPI_MPLEX_CS1 [2]
SPI_CLK [2]

20
1

12

17
16
15
13

2
3

CCFL_GND

U100
LX1689

EA_IN

OC_SNS
OV_SNS
I_SNS
EA_OUT

DIM_MODE
DIV_248
BRITE_C
BRITE_IN
BRITE_R
BRITE_OUT
I_R

A_OUT
B_OUT

B/W to color data converter

10R
10R
10R
10R
150R

10R
10R
10R
10R
10R
10R
10R
10R
10R
10R

GND

CO100_1
100nF

V_batt
ENABLE

CO100_2
100nF

19
4

5
6
7
9
8
14
11

18
10

Mainboard connection

MicroMatch20`/SMD

1
3
5
7
9
11
13
15
17
19

+3.3V VCC_OUT

R111
10K

R112
10K

R103
10K

R106
10K

R100
10K

R101
10R

R102
10R

8
7
1

VCC_OUT

5
6
3

C101
100nF

10
VDD

1
VDD

GND
6

T100

2
1

2
1

6
7

VCC_OUT

2
1

CCFL inverter

4
PR

2
1

VCC_OUT

VCC 16

GND

10
PR

rev. 1.0 - 12/2009

TOUCH
SCREEN

Service Manual
075.1

Display board - board 1 (2994502X)

10-7

[1] SPI_TOUCH_CS

[1] SPI_MPLEX_CS1
[1] SPI_MPLEX_CS2

[1] SPI_ADC_DATA_OUT
[1]
SPI_CLK

GND

CO200
100nF

+3.3V

GND

G1
G2A
G2B

CO210
100nF

R203
10K

6
4
5

A
B
C

R202
10K

1
2
3

+3.3V

R201
10K

+3.3V

R200
10K

+3.3V

+3.3V

16
VCC
GND
GND

15
14
13
12
11
10
9
7

U200
74HC138

Y0
Y1
Y2
Y3
Y4
Y5
Y6
Y7
SPI_KEYBOARD_CS

11
3.3

10

U104E
74HC14_3

10

13

12

11

OE

SLOAD

RCK

SCK

QH

A
B
C
D
E
F
G
H

GND

14

15
1
2
3
4
5
6
7

U210
74HC589

SER

+3.3V

GND

R210
10K
GND

R211
10K
GND

Keyboard readout

16
VCC
GND

10-8
8

SPI Chip Select


demultiplexer

GND

R212
10K

R213
10K

+3.3V

JST4

1
2
3
4

J210

Key
board

075.1
Service Manual

Display board - board 2 (2994502X)

rev. 1.0 - 12/2009

Service Manual

075.1

JST4

1
2
3
4

J100

Display
board

Keyboard (2994508D)

SW102
CLEAR

SW101
STOP

SW100
START

rev. 1.0 - 12/2009

10-9

075.1

Service Manual

Motor relay board - 230V (2975500D)


J1
1
2
3
D1
1N4004

D2
1N4004

4
5
6
7

D3
S1
SW DPST

RE1

12V

D4
RE2

12V

8
CON8

T1
51

R3

C2

33R

10nF

J3
R1

C1

100R

100nF/1250V

230V

T2

55

S2

JST7

T3
52
"BLEEDER"

R2
10K/2W
J2
72

T4

73

124

74
T5
54

10-10

rev. 1.0 - 12/2009

Service Manual

075.1

Motor relay board 115V (2975540V)


J1

1
2
3
D1

D2

1N4004

1N4004

4
5
6
7

D4

D3
S1

RE1

12V

12V

RE2

CON8

SW DPST

T1

51

R3

C2

33R

10nF

J3

R1

C1

100R

100nF/1250V

3
115V

4
5

T2

55

JST7

S2
T3
52
"BLEEDER"

R2
10K/2W

J2

72

T4

73

124

74

T5
54

rev. 1.0 - 12/2009

10-11

10-12
Connection board

1
2
3
4
5
JST5

J101

FRAME

3
NC

NC

6
A
B
4

1
GND

5
GND

U100
SN65220DBVR
GND 2

GND

1
2
3
4
DD+
GND

S2

PC

FRAME

J100
Kycon KUSB-SMT-BS1N-W
V+
S1 5

075.1
Service Manual

Connection board - regular (2992003U)

rev. 1.0 - 12/2009

GND

MOD_VCC
MOD_RxD
MOD_TxD
MOD_CTS
MOD_RTS
MOD_RESETn
MOD_MUTE
FIF_RxD
FIF_TxD

JST12

1
2
3
4
5
6
7
8
9
10
11
12

GND

+3.3V

R108
180R

R103
180R

GND

C105
100nF

C103
100nF

V+

C2-

C2+

C107
100nF

CASE

H101
4.0 mm

GND

C111
100nF

+3.3V

C118
47pF

H102
4.0 mm

R107
4K7

R102
4K7

15
10

13
12

GND

C119
47pF

H104
4.0 mm

C106
100nF

C104
100nF

GND

R111 4K7

GND

H103
4.0 mm

V-

C1-

C1+

EN

T1IN
T2IN

GND

CO103
100nF

R1OUT
R2OUT

GND

SHDN

T1OUT
T2OUT

R1IN
R2IN

+3.3V

GND

20

17
8

16
9

IC103
MAX3222E

R112 4K7

Mounting holes

GND

CO108
100nF

19

VCC

GND

18

J108

+3.3V

C113
100nF
GND

2 BP
3 + V-

GND

GND

IC102
LM4818

CO102
100nF

L1
L2

+3.3V

R104
470k

4 1 SD V+

C120
100nF

R105
470k

6
7

GND

LS101
41.T70P015H

C108
100nF

GND

R110
4k7

GND

CO101
100nF

+3.3V

CON9

1
2
3
4
5
6
7
8
9

J112

CON9

1
2
3
4
5
6
7
8
9

J113

43
42
41
40
39
38
37
36
35
34
33

64
63
62
61
60
59
58
57
56

LED_DCD
LED_RX
LED_DTR
LED_TX

GND

MIC+
MICRESET

TCLK
RCLK

TX+
TXRX+
RX-

Phone_Tip
Phone_Ring

MOD100
SOCKET MODEM

SPK+
SPKGND
DTR
DCD
CTS
DSR
RI
TxD
RxD
RTS

SPKR
AGND
MICV
VCC
LED_SPD
LED_COL
LED_LINK
LED_ACT
LED_FDX

1
2
3
4
5
6
7
8
9

JST5

1
2
3
4
5
CASE

CON9

J111

1
2

J109
CON2

J105

29
30
31
32

26

22
23
24

11
12

4
5
6
7

1
2

C114
C115
C116
C117

B103
B105
B104
B106

GND

47pF
47pF
47pF
47pF

BEAD
BEAD
BEAD
BEAD

D101
SMTPA220

R121
4R7

NC

NC

R122
4R7

CASE

GND

GND

R109
180R

F101
TRF600-150

IC104
SN65220DBVR
GND 2

JST4

1
2
3
4

J103

R123
4R7

C123
CASE
1nF/1kV

C122
1nF/1kV

R120
4R7

6
A
B

rev. 1.0 - 12/2009


4

+3.3V

S2

S1

1
6
2
7
3
8
4
9
5

J106
USB Device

V+
DD+
GND

J107
FIF connector

1
2
3
4

10

CASE

CASE

11

10

RJ45 Connector

1
2
3
4
5
6
7
8

J104

J102
RJ11 Connector

6
5
4
3
2
1

Service Manual
075.1

Connection board - expanded (2992001S)

10-13

H1
4.0 mm

H2
4.0 mm

B101
B102
B103
B104
B105

H3
4.0 mm

BEAD
BEAD
BEAD
BEAD
BEAD

Mounting holes

JST3

1
2
3

J101

CASE

NM

GND

C112 47pF NM

R106 1K

H4
4.0 mm

27R

R109

R112
10K

R101
0R

PB4

[2]

C101
100F
Low ESR

C102
100nF

R107
R108

GND

1R
1R

(Remark: the ring is open on the


side opposite of the side of all
the JST connectors).

GND

VCC

Sense

D Col

TCap

Comp

S Em

S Col

TP101 GND
TP102 GND

GND

IC101
MC34063A

CASE is implemented as a guard ring


of 3mm on all layers. The ring is
'stitched' together by vias placed
on every 4 mm.

GND

TP106
GND

74LVC14A

IC204E
10
11

G100 GNDSTER

F101
MF-SM050
NM

TP105
+24V

+24V_INT

GND

+3.3V

14

74LVC11

GND

VCC

IC201D

R102
470R

14

C103 47pF
C113 47pF
C114 47pF

74LVC14A

GND

VCC

IC204G

R103
470R

14

74LVC14A

GND

VCC

IC405G

R105
470R

STPS1L40A

R104
470R

GND

D101

L102
220H

Power of logic gates devices

1
2

14

C104

74LVC32

GND

VCC

IC407E

GND

100nF

C105
220F
Low ESR

GND

GND

100nF

C109

+5V

VIN

VIN

IC103

C106
100nF

IC102

D102
STPS1L40A

2
4

GND

VOUT
CASE

2
4

LD1117_25/SOT223

GND

VOUT
CASE

LD1117_33/SOT223

GND
1

10-14
GND

GND

C110
100nF

GND

C107
100nF

GND

C111
100F
Low ESR

+2.5V

GND

C108
100F
Low ESR

+3.3V

075.1
Service Manual

Communication board - Power supply (2992000R)

rev. 1.0 - 12/2009

EP_RST

[4]

nRESET

[3,5]

GND

CO200_7

100nF

CO200_6

GND

100nF

10nF

100nF

10nF

CO200_5

100nF

VDDIO

GND

CO201

CO200_3

10nF

CO200_8

100nF

CO203

JTAG Debug Port

+3.3V

1
3
5
7
9
11
13
15
17
19

74LVC32

100nF

CO200_9

100nF

CO204

J201
HEADER 10X2
NM

10

IC407C

IC204B
74LVC14A

TDO
nSRST

R250 10K
R251 10K
R252 10K
R253 10K
R254 10K
nTRST
TDI
TMS
TCLK

10nF

100nF

GND

VDDIO

10nF

100nF

CO200_13

B202

B201

+2.5V

10nF

TDO

TRST
TDI
TMS
TCLK

TEST1
TEST0

DSR1
DCD1
CTS1
TXD1
RXD1

TXD2
RXD2

PHDIN
LEDDRV

RUN/CLKEN
EXPRDY
EXPCLK
URESET
POR
BATOK
EXTPWR
WAKEUP
PWRFL
BATCHG
MEDCHG/BROM

XTAL32OUT

XTAL32IN

XTALOUT

XTALIN

VCORE

GND

GND

100nF

CO200_1

VOSC

VOSC

CO200_14

BEAD

BEAD

22

125
11
58
90

39
40

R216

10K

38
37
35
32
36

EP_nRXF
EP_HOST
EP_nTXE
EP_TXD
EP_RXD

9
10

FIF_TXD
FIF_RXD

R212

[4]
[4]

R210
R211

R208
R209

49

7
8
4
156
154
10K
153
10K
152
WAKEUP 161
10K
162
10K
151
155
10K
34
31
10K

IC204A
74LVC14A
R207

50

159

158

R201
27R

[4]
[4]
[4]
[4]
[4]

GND

+3.3V

+3.3V

GND

+3.3V

+3.3V

C209
10nF

R204 10K

10pF

C201

CO200_12

BEAD

BEAD

GND

C208
10nF

CO200_11

B204

B203

+3.3V

CO200_10

GND

IC201C
74LVC11

R255 10K
R256 10K
R257 10K

9
10
11

R203 10K
WAKEUP

X201
3.6864 MHz

74LVC14A

Test Interface

GND

100nF

C207

2
4
6
8
10
12
14
16
18
20

74LVC14A

IC204D
9

+3.3V

74LVC14A

IC204F
13
12

nFMRST

GND

R202 10K

10pF

C202

C205
47pF

Serial I/O

VCORE

RESET

[4,5]

[4] EP_BOOTSEL

IOCHRDY

[5]

C214
100nF

CO200_4

F3686KHZ

ADCOUT
ADCIN
ADCCS
ADCCLK
SMPCLK

EXTFIQ
EINT1
EINT2
EINT3

IRQs

IC200A

PA0
PA1
PA2
PA3
PA4
PA5
PA6
PA7
PB0
PB1
PB2
PB3
PB4
PB5
PB6
PB7
LEDFLSH/PD0
PD1
PD2
PD3
PD4
PD5
BOOTSEL0/PE0
BOOTSEL1/PE1
CLKSEL/PE2

DRIVE0
DRIVE1
FB0
FB1

SCLK/PCMCLK/SSICLK
SDOUT/PCMOUT/SSITXDA
SDIN/PCMIN/SSIRXDA
LRCK/PCMSYNC/SSITXFR
MCLKIN/SSIRXFR
MCLKOUT/BUZ

SSI2 DAI Codec

VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSCORE
VSSCORE
VSSRTC
VSSOSC

[4]

2
21
57
74
89
107
123
139
167
183
197
72
181
51
157
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDCORE
VDDCORE
VDDRTC
VDDOSC
General Purpose I/O

10nF

CO200_2

Place beads B201 to


B204 close to EP7312

EP7312 Main

3
12
33
64
73
81
98
108
116
124
140
149
168
174
182
190
198
203
71
180
48
160

VCORE VOSC

30
29
28
27
26
25
24
23
20
19
18
17
16
15
14
13
62
61
60
59
56
55
47
46
45

76
75
82
80

63
66
67
65
68
93

78
69
70
77
79

44
43
42
41

GND

R227
R228
R229

PD0
PD1
PD2
PD3
PD4
PD5

PB0
PB1
PB2
PB3
PB4

R220
R221
R222
R223
GND

10K
10K
10K
10K

10K
10K
10K

GND

PD[0-5]

+3.3V

R224 10K
R225 10K NM
R226 10K NM

+3.3V

PB[0-4]

GND

R231
R232
R233
R234
R235
R236
D201
D202
D203
D204
D205
D206

Board
Version
bits

+3.3V

470R
470R
470R
470R
470R
470R
GRN603
GRN603
GRN603
GRN603
GRN603
GRN603

R246
1K

R245 15K

R242 10K

R240 10K
R241 10K

+24V_INT

R259 10K NM
R260 10K
R261 10K
GND

nFMRST

+3.3V
JP201
RST MOD
R230 10K
1
2
3
R238 1K
NM
GND

nUSBINT [5]
nUARTINT0 [4]
nUARTINT1 [4]
LANINT [5]

+3.3V
R237
10K

R205
10K

PFO/CAL TP208

GND

+3.3V

TP205 PB5
TP206 PB6
TP207 PB7

10K

R218

TP203 SCLK

10K

TP201 SDO
TP202 SDI
R217

R258
10K

+3.3V

PD0

VDDIO

PD1

IC204C
5

PD2

PD3

IC203

PB0
PB1
PB2
PB3
PB4

PFI

GND

1
2

10

10K

10K

PB0
PB1
PB2
PB3
PB4

R248

R247

FM3104

VBAK

CNT1
CNT2

X1

X2

11

PFO/CAL

RST

A0
A1

SCL
SDA

TESTLED0
TESTLED1
TESTLED2
TESTLED3
TESTLED4
TESTLED5

3
4

13
12

+3.3V

14
VDD

R200
27R

PD4

Reset, Clock, and Power Controller


PD5

PWM

GND

rev. 1.0 - 12/2009


SSI1 ADC

Place IC204, R200, and R201 near


EP7312 and keep track length from
XTALOUT to input 5 of IC204 very
short

[4]
[4]
[4]
[4]
[1]

BT201
CR1632 (3V)

GND

X203
2 32.768 kHz

Service Manual
075.1

Communication board - CPU core (2992000R)

10-15

D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
D17
D18
D19
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31

CO301_3

10nF

100nF

100nF

GND

10nF

CO303_1

100nF

+3.3V

CO303_2

10nF

CO301_1

+3.3V

GND

CS0
CS1
CS2
CS3
CS4
CS5
HALFWORD
WORD

CO302_1

+3.3V

GND

SDCLK
SDCKE
PD6/SDQM0
PD7/SDQM1
SDQM2
SDQM3
SDCS0
SDCS1

A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
BA1/A13
BA0/A14
DRA12/A15
DRA11/A16
DRA10/A17
DRA9/A18
DRA8/A19
DRA7/A20
DRA6/A21
DRA5/A22
DRA4/A23
DRA3/A24
DRA2/A25
DRA1/A26
DRA0/A27

MOE/SDCAS
WRITE/SDRAS
MWE/SDWE

Static Memory IF

CO302_2

Keyscan Interface

IC200B
EP7312 External Bus

COL0
COL1
COL2
COL3
COL4
COL5
COL6
COL7

CL1
CL2
DD0
DD1
DD2
DD3
FRM
M

D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
D17
D18
D19
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31

LCD Interface

92
91
88
87
86
85
84
83

185
184
192
191
189
188
186
187

179
177
175
172
170
166
164
150
147
145
143
141
137
135
133
131
129
127
122
120
118
115
113
111
109
104
102
100
97
96
95
94

nCS0
nCS1

100nF

10nF

100nF

CO302_5

100nF

CO301_5

100nF

10nF

CO304_2

CO301_2

10nF

23
24
25
26
29
30
31
32
33
34
22
35
36
20
21

nSDCS0
nRD
nSDRAS
nWR

[4,5]

[5]
[4]
[4]

nCS2

nCS3

nCS4

nCS5

10nF

CO301_6

10nF

CO302_6

[4]
[5]

nCS1

[4,5]

nWR

28
41
54

100nF

CO301_7

100nF

VCC
VCC
VCC

VCCQ
VCCQ
VCCQ
VCCQ
27
14
1

49
43
9
3

2
4
5
7
8
10
11
13
42
44
45
47
48
50
51
53

+3.3V

D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15

GND

nSDCS0
nRD
nSDRAS
nWR

SDCLK
SDCKE
SDQM2
SDQM3

A27
A26
A25
A24
A23
A22
A21
A20
A19
A18
A17
A16
A15
A14
A13

GND
GND
GND

VSSQ
VSSQ
VSSQ
VSSQ

CS
CAS
RAS
WE

CLK
CKE
DQML
DQMH

A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
NC/A12
BA0
BA1

VCC
VCC
VCC

VCCQ
VCCQ
VCCQ
VCCQ

DQ0
DQ1
DQ2
DQ3
DQ4
DQ5
DQ6
DQ7
DQ8
DQ9
DQ10
DQ11
DQ12
DQ13
DQ14
DQ15

IC302

MT48LC4M16/SO
or IS42S16400B-7T

28
41
54

6
12
46
52

19
17
18
16

38
37
15
39

23
24
25
26
29
30
31
32
33
34
22
35
36
20
21

SDRAM is upgradeable to from 4Mx16 to 32Mx16 devices.


Pin 36 will be NC on 4Mx16 and 8Mx16 devices, and A12
on the larger capacity devices

MT48LC4M16/SO
or IS42S16400B-7T

GND
GND
GND

VSSQ
VSSQ
VSSQ
VSSQ

CS
CAS
RAS
WE

CLK
CKE
DQML
DQMH

DQ0
DQ1
DQ2
DQ3
DQ4
DQ5
DQ6
DQ7
DQ8
DQ9
DQ10
DQ11
DQ12
DQ13
DQ14
DQ15

IC301

A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
NC/A12
BA0
BA1

CO302_7

GND

19
17
18
16

SDCLK
SDCKE
SDQM0
SDQM1

6
12
46
52

38
37
15
39

A27
A26
A25
A24
A23
A22
A21
A20
A19
A18
A17
A16
A15
A14
A13

nRD

R303 0R
Place near EP7312

CO302_4

CO304_1

CO301_4

100nF

A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23
A24
A25
A26
A27

SDQM2
SDQM3

CO302_3

204
205
206
207
208
1
105
5

202
6
201

200
199
54
53
196
195
194
193

178
176
173
171
169
165
163
148
146
144
142
138
136
134
132
130
128
126
121
119
117
114
112
110
106
103
101
99

D[0..31]

+3.3V

D16
D17
D18
D19
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31

[2,5]

GND

C301
10pF
NM

R304
0R
NM

SDCLK

25
24
23
22
21
20
19
18
8
7
6
5
4
3
2
1
48
17
16
9
10
13

nRESET

AM29LV320
or M29W320DT
or MBM29DL640E

nRD 28
nCS0 26
nWR 11

A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23

C302
10pF
NM

R305
0R
NM

Place termination networks


near SDRAMs

27
14
1

49
43
9
3

2
4
5
7
8
10
11
13
42
44
45
47
48
50
51
53

GND

OE
CE
WE

A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
NC

IC303

470R

R301

WP/ACC

BYTE

RESET

RY/BY

DQ0
DQ1
DQ2
DQ3
DQ4
DQ5
DQ6
DQ7
DQ8
DQ9
DQ10
DQ11
DQ12
DQ13
DQ14
DQ15

+3.3V

27

A[1..27]

Vss

37
Vcc
Vss
46

14

47

12

15

29
31
33
35
38
40
42
44
30
32
34
36
39
41
43
45

D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15

R306 10K
R307 10K

+3.3V

25
24
23
22
21
20
19
18
8
7
6
5
4
3
2
1
48
17
16
9
10
13

nRD 28
nCS0 26
nWR 11

A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23

GND

OE
CE
WE

A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
NC

IC304

RY/BY

14

47

12

15

D16
D17
D18
D19
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31

[4,5]

AM29LV320
or M29W320DT
or MBM29DL640E

WP/ACC

BYTE

RESET

29
31
33
35
38
40
42
44
30
32
34
36
39
41
43
45

A[1..27]

DQ0
DQ1
DQ2
DQ3
DQ4
DQ5
DQ6
DQ7
DQ8
DQ9
DQ10
DQ11
DQ12
DQ13
DQ14
DQ15

+3.3V

Vcc

37
Vss

10-16

SDRAM Interface

Vss

Data Bus

27

Address Bus

46

+3.3V

RED603
FLASH
WRITE

D302

R302
470R

D[0..31]

[4,5]

075.1
Service Manual

Communication board - CPU memory (2992000R)

rev. 1.0 - 12/2009

nWR

nCS4

nCS5

[3,5]

[3]

[3]

nUARTINT1

F3686KHZ

EP_RXD

EP_TXD

[2]

[2]

[2]

[2]

nCS1

nCS4
nCS5

EP_RST

[3]

[2]

[2] EP_BOOTSEL

nUARTINT0

[2]

D[0..31]

[3,5]

nRD

[3,5]

RESET

A[1..27]

[3,5]

[2,5]

FIF_RXD

[2]

5
4
3

D0
D1
D2
D3
D4
D5
D6
D7

1
19

2
3
4
5
6
7
8
9

74LVC32

74LVC32
IC407B

IC407A

[2]
[2]

GND

DIR
OE

18
17
16
15
14
13
12
11

BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7

A2
A3
A4

13

GND

+3.3V

R442

74LVC14A

14

13

30
29

36

10
11

19
15

28
27
26

44
45
46
47
48
1
2
3

1K

10K

10K

R441

R422
R423
R424
R425

+3.3V

10K

10K
10K
10K
10K

HW ID = 1

R417

R416

10K

R427

1K

+3.3V

R443
10K

R426

+3.3V

BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7

BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7

26
41

30
29
28
27

40
39
38
37
36
35
33
32

21
19
16
17

20

22

24
23

10
15
13
12
11

XTAL2

XTAL1

INT0
INT1

GND

SI/WUB
PWREN

RXF#
TXE#
RD
WR

FIFO D0
FIFO D1
FIFO D2
FIFO D3
FIFO D4
FIFO D5
FIFO D6
FIFO D7

CTS
DSR
RI
DCD

DTR

RTS

TXD
RXD

9
18
6
4
8
22
23
35
20
16
21

32
31
43
5
7
33
38
34
39
40
41

+3.3V

IC401
SC16C2550B

OUT1
RXRDY1
TXRDY1
RXD1
TXD1
RTS1
CTS1
DTR1
DSR1
CD1
RI1

OUT0
RXRDY0
TXRDY0
RXD0
TXD0
RTS0
CTS0
DTR0
DSR0
CD0
RI0

SI/WUA
TXDEN
SLEEP
RXLED
TXLED

RESET

CS0
CS1

RD
WR

A0
A1
A2

D0
D1
D2
D3
D4
D5
D6
D7

Hardware ID bits:
CTS = Bit 0
DSR = Bit 1
RI = Bit 2
DCD = Bit 3

BD[0-7]

+3.3V

IC405F
12

+3.3V

EP_nRXF
EP_nTXE

IC406
74LVC245

B1
B2
B3
B4
B5
B6
B7
B8

74LVC14A

IC405B
4
3

+3.3V

A1
A2
A3
A4
A5
A6
A7
A8

74LVC14A

IC405E
11

nWR

74LVC11

IC201B

nRD

D[0..31]

10

RESET

nCS5

nCS4

nWR

nRD

A[1..27]

+3.3V

42
VCC
GND
17

FIF_TXD

10K
10K
10K

GND

+3.3V

+3.3V

C402
100nF

C401
100nF

10K

R409

GND

24

28

22
23

19
18
17
16
15

14
13
12

R444
R445
R446
R447

3V3OUT

IC404
FT2232

TEST

EEDATA

EESK

EECS

RESET

XTOUT

XTIN

RSTOUT

47

48

44

43

8
7

R430 4K7
R438 4K7

R429
1K

GND

C409 10nF
C412 10nF
C411 10nF

R428
470R

GND

100nF GND

C410

1
2
3
4

93C46

CS
SK
DIN
DOUT

IC408

R433
10K

R432
4K7

24

28

R431
10K

8
7
6
5

C419
100nF

C418
47pF

VCC
NC
NC
GND

GND

GND

C406
100nF

C405
100nF

10K

22
23

19
18
17
16
15

R420
R421
R439
R440
R410

14
13
12
10K
10K
10K
10K

PB0
PB1
PB2
PB3

GND

GND

USB DM (-)
USB DP (+)

R411
470R

R406

GND

10K

R401
R402
R403

+5V

31
14
VCCIOB
VCCIOA

[2]

20

VCC

GND

42
3
VCC
VCC

GND
GND
GND
GND
34
25
18
9

10

46
AVCC
AGND
45

+3.3V

R1IN
R2IN
R3IN
R4IN
R5IN

T1OUT
T2OUT
T3OUT

+3.3V

R1IN
R2IN
R3IN
R4IN
R5IN

T1OUT
T2OUT
T3OUT

+5V

20
21

4
5
6
7
8

9
10
11

[5]

GND

100nF

C408
100nF

C407
100nF

C404
100nF

C403
100nF

100nF

CO402

F6MHZ

GND

GND

CO401

+3.3V

IC403
MAX3243/SO

27

V+

C2-

C2+

EP_HOST [2]

GND

V-

C1-

C1+

27

20
21

4
5
6
7
8

9
10
11

IC402
MAX3243/SO

V+

C2-

C2+

FORCEOFF R2OUTB
FORCEON INVALID

R1OUT
R2OUT
R3OUT
R4OUT
R5OUT

T1IN
T2IN
T3IN

V-

C1-

C1+

FORCEOFF R2OUTB
FORCEON INVALID

R1OUT
R2OUT
R3OUT
R4OUT
R5OUT

T1IN
T2IN
T3IN

10K
10K
10K
10K

26
VCC
GND
25
26
VCC
GND

rev. 1.0 - 12/2009


25

[2]
[2]
[2]
[2]

74LVC14A

IC405D
8

74LVC14A

IC405C
6

100nF

CO403

R434
R435

100nF

CO404_1

27R
27R

+5V

GND

74LVC14A

IC405A
1
2

12

BEAD
BEAD
BEAD
BEAD

BEAD

BEAD

BEAD
BEAD
BEAD
BEAD

B412
B413
B416
B417

74LVC32

IC407D

OUT
R414
470R

100nF

CO404_2

C414
47pF
NM

100nF

GND

100nF

CASE

GND

GND

+3.3V

100nF

CO407

GND

+5V

R413
10K

11

CO406

C415
47pF

R418
1K

CO405

GND

GND

IC409 OSC 6MHz


4 VCC
TS 1

13

B409
B414
B415

R415
10K

BEAD
BEAD
BEAD

B405
B406
B407
B408

BEAD
BEAD
BEAD
BEAD

B401
B402
B403
B404

B411

B410

J401

100nF

100nF

CO409

+5 Volt
DataData+
GND
SHIELD

AUX_DCD
AUX_RxD
AUX_TxD
AUX_DTR
AUX_GND
AUX_DSR
AUX_RTS
AUX_CTS

Auxilliary
Port

To
Connector
Board

100nF

CO404_3

10nF

CO404_4

USB
Device

MOD_VCC
MOD_RxD
MOD_TxD
MOD_CTS
MOD_RTS
MOD_RESETn
MOD_MUTE
FIF_RxD
FIF_TxD
FIF_CTS
FIF_RTS
GND

CO408

+5V

JST5

1
2
3
4
5

J403

JST8

1
2
3
4
5
6
7
8

J402

JST12

1
2
3
4
5
6
7
8
9
10
11
12

Service Manual
075.1

Communication board - Peripheral I/O (2992000R)

10-17

RESET

nWR

[3,4]

nCS3

[3]

nUSBINT

A[1..27]

[3,4]

nRESET

[2]

D[0..31]

[3,4]

IOCHRDY

nRD

[3,4]

[2]

nCS2

[2,4]

[3]

[2,3]

A[1..27]

D[0..31]

+3.3V

GND

10K NM
10K NM

10K NM

R503

10K NM
10K NM

R506

R507
R508

10K

R531

A3

A2

13
2
1

R530 10K

R532 10K
R533 10K
R534 10K

+3.3V

12

74LVC11

IC201A

GND

10K NM

R505

X501
20MHz
NM NM
NM

10K NM

R504

10K NM

R501
R502

R510 10K 1%
R511 10K 1%

A1
A2
A3

D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15

25
26
27
28
34
29
30
31
32

21
22
23

59
60

63
64
2
3
4
5
6
7
9
10
11
12
13
14
16
17

97
98

77
76
93

2
3
4
5
6

75
63
29
28
34
49
61
62
33
64
36
7
17

37
38
39
40
41
42
43
44
45
46
47
48
50
51
52
53
54
58
59
60

DREQ1
DREQ2
DACK1
DACK2
EOT
INT1
INT2
TEST
RESET

CS
RD
WR

A0
A1

D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15

IC501

+3.3V

XTAL1
XTAL2

HWSLEEP
TESTSEL
RES

ELCS
EECS
EESK
EEDATAOUT
EEDATAIN

RESET
AEN
MEMR
MEMW
MEMCS16
REFRESH
IOR
IOW
IOCS16
IOCHRDY
SBHE
CHIPSEL
CSOUT

SA0
SA1
SA2
SA3
SA4
SA5
SA6
SA7
SA8
SA9
SA10
SA11
SA12
SA13
SA14
SA15
SA16
SA17
SA18
SA19

56

VHOLD2

VHOLD1

GND

43

41
44

39

48
49

50
51
52
53

55
54

47
46

38
33

40
42
37
36

24

19

DI+
DICI+
CIDO+
DOTXD+
TXDRXD+
RXD-

DMACK0
DMACK1
DMACK2

DMARQ0
DMARQ1
DMARQ2

INTRQ0
INTRQ1
INTRQ2
INTRQ3

SD0
SD1
SD2
SD3
SD4
SD5
SD6
SD7
SD8
SD9
SD10
SD11
SD12
SD13
SD14
SD15

10K

C511 100nF

R551

R538

F6MHZ

[4]

100nF

CO500_2

8R2

R522 NM

8R2

R521 NM

10nF

CO501_2

+3.3V

R516
470R
NM

NM

[2]

R545
R546

R541
R542

CO500_3

CO500_4
10nF
NM

CO500_5
100nF
NM

27R
27R

27R
27R

C516
47pF

C514
47pF

T501
TG41-2006N
NM

10

15

GND

GND

R547 C517
15K
47pF

R543 C515
15K
47pF

GND

GND

R548
15K

R544
15K

GND

GND

CASE

+5V

CASE

+5V

GND

JST4
NM

1
2
3
4

J501

LAN
(10 Mb Ethernet)

JST6

1
2
3
4
5
6

J503

JST6

1
2
3
4
5
6

J502

+5 Volt
DataData+
GND
SHIELD

+5 Volt
DataData+
GND
SHIELD

USB Host #2

USB Host #1

OPTIONAL LAN (992006)

C505
100nF/1KV
NM

100nF
NM

CO500_7

+3.3V

GND

CO500_6
10nF
NM

C504
100nF/1KV
NM
GND

16

14

6
3

11

Place R521, R522, R523, and C501


very close to CS8900A (See Cirrus
AN83, page 44 & 45)

100nF
NM

C502
C503
100nF
100nF
NM
NM
GNDGND

R523
100R
NM

C501
560p
NM

100nF
NM

LANINT

10nF
NM

CO500_1

470R +3.3V
R515

+3.3V

GND

CO501_1

D502
NM
GRN603 ACTIVE

+3.3V

GND

10K NM

10K
NM

R512

+3.3V

D501
NM
GRN603 LINK

R513

D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15

GND

78
99
100

79
80
81
82
83
84
87
88
91
92

16
14
12

15
13
11

32
31
30
35

65
66
67
68
71
72
73
74
27
26
25
24
21
20
19
18

TP501 DDTP502 DD+


10K

10K

10K

R536

R537

10K

R535

GND

C510 100nF

BSTATUS/HC1
LINKLED/HC0
LANLED

+3.3V

ISP1161A1

XTAL1

CLKOUT
XTAL2

DVBUS

DDDD+

H1DH1D+
H2DH2D+

HOC2
HOC1

HPSW2
HPSW1

GL
NDPSEL

HWAKEUP
HSUSPEND
DWAKEUP
DSUSPEND

VCC

IC500
CS8900A-CQ3
NM

8
10
23
55
57
58
VREG

1
8
15
18
35
45
62
57

+3.3V

DVSS1
DVSS1A
DVSS2
DVSS3
DVSS3A

DGND
DGND
DGND
DGND
DGND
DGND
DGND
AGND

9
22
56
69
DVDD1
DVDD2
DVDD3
DVDD4

90
85
95
AVDD1
AVDD2
AVDD3
AVSS0
AVSS1
AVSS2
AVSS3
AVSS4
DVSS4

10-18
1
89
86
94
96
70

075.1
Service Manual

Communication board - LAN and USB host (2992000R)

rev. 1.0 - 12/2009

GND

+5V

CO106
10nF

GND

+24 Volt
GND
COVER out
COVER in
Motor run relay
Motor start relay
GND
GND

Unit
power

Side
cover

Top
cover

1
2
3

1
2
3
4
5
6
7
8

R125
1K

JST8

J102

JST3

J101

JST3

1
2
3

CASE

GND

MH100
MOUNTING
HOLE

GND

GND

R111
4K7

R107
56R

R105
6K8

R102
6K8

R100
6K8

R110
4K7

GND

R108
1K

GND

R103
1K

GND

R101
1K

12

10

GND

GND

GND

11

13

U804F
74HCT14_5

U804E
74HCT14_5

C118
10nF

C111
10nF

C100
10nF

GND

GND

TP103
GND

R117
150R

R115
1K

C127
1nF

R118
8K2

R116
10K

24V_IN

TP105
+24V

GND

+5V

GND

C129
1nF

3 +

GND

R124
1K

GND

+5V

POWER_DOWN [2]

IN_START_RELAY [2]

IN_MOTOR_RELAY [2]

U106B
LM358

7
CO150
10nF

CO151
10nF

GND

C102
220F

GND

GND

CO152
10nF

CO153
100nF

CO154
100nF

CO155
100nF

R119
150R

OUTPUT

FEEDBACK

GND

GND

D100
STPS340U

L100
47H

C119
100nF
GND

C120
100nF
GND

C121
100nF

2
3
6
7
VIN
VIN
VIN
VIN

C130
100nF

C128
220F
3
VCC

R114
0R1

GND

The information contained herein is the


property of Neopost Technologies BV,
Drachten, the Netherlands. Any copying
or reproduction of this document in any
form and/or disclosure to other parties
without the express written consent of
Neopost Technologies BV is strictly
prohibited.

GND

GND

24V_IN

GND

C104
220F

+5V

GND

GND

R121
10K

C126
100nF

24V

GND

U103
79L12

VOUT

NM

+5V
TP100

GND

C113
100nF

Vin

GND

2K7

Vout
TAB

2
4

Vin

U102
LD1117/S25

GND

GND

Vout

2
4

L103

C123
100nF

2K7

L101

TAB

GND

24V

D104
12V

GND

C131
100nF

+12V

NM

TP102
+12V

C124
1nF

L104

L102

GND

C114
100F

+2.5V

GND

C108
100F

+3.3V

+12V power supply

Otto Tuil

Common Power
Code:

time: 11:49:22

2825900V
Modified: Wednesday, August 20, 2008

Drawn:

2.5V power supply

GND

C105
100nF

U101
LD1117/S33

3.3V power supply

VCC_OUT

GND

C115
100nF

AVREF

GND

C125
100F

2K7

2K7

R104
100R

Size

A3

Sheet 1

of 12

01

Rev:

Andromeda A1/DS-70 mainboard

MAIN_CURRENT [4]

TP101
-12V

Title:

C122
100nF

C144
1uF

GND

GND

-12V

GND

C106
100nF

TECHNOLOGIES BV
PO BOX 20 9200 AA DRACHTEN
DE TIJEN 3 DRACHTEN THE NETHERLANDS
TEL: +31 512 589 300 / FAX: +31 512 589 399

R120
10K
U105
MAX4376T

OUT

CURRENT MEASUREMENT

GND

-12V power supply

R112
82R

R109
82R

C110
100nF

C117
100nF

GND

D102
BAT54S

+12V

C116
100nF

GND

C109
100nF
NM

FLAG

GND

C103
100nF

IN

U100
LM2593

DELAY

5V power supply

TAB
8

VCC_OUT
Spread arround the board
to decouple VCC_OUT

C101
220F

24V

GND

IN_COLLATOR_COVER [2]

IN_SIDE_COVER [2]

IN_TOP_COVER [2]

75mSec time left


for uC after powerdown

U106A
LM358

Power down interrupt

R113
10K

24V

GND

Q100
BC817

R106
56R

COVERTRACK2

GND

COVERTRACK1

Q101
BC817

CASE

GND

F100
3A

24V_IN

24V

SD/SS
7

J100

GND
4
4
R+

1
2
5
R-

GND
5

GND
1
GND
1

GND

+
+

rev. 1.0 - 12/2009

Cover
switches

Service Manual
075.1

Main board - Common power (2825900V)

10-19

ARM_PORn

+3.3V

+3.3V
+3.3V

1
3
5
7
9
11
13
15
17
19

HEADER 10X2

J200
2
4
6
8
10
12
14
16
18
20

GND

10K
10K
10K
10K
10K

R210

R209
R208

GND

R223
10K

40
39

22
156

125
11
58
90

38
37
35
32
36

9
10

34
31

10K

10K
10K

153
152
161
162
151
155

154

10K
10K

GND

C203
100nF

+3.3V

GND

RESIN
SEN
CT

GND

C204
1uF
T=26mSec

2
7
3

+5V

U203
TL7702A

RSET
RST
REF

TEST0
TEST1

TDO
URESET

TRST
TDI
TMS
TCLK

DSR1
DCD1
CTS1
TXD1
RXD1

TXD2
RXD2

PHDIN
LEDDRV

BATOK
EXTPWR
WAKEUP
PWRFL
BATCHG
MEDCHG/BROM

POR

RUN/CLKEN
EXPRDY
EXPCLK

XTAL32IN
XTAL32OUT

XTALIN
XTALOUT

C205
100nF

GND

GND

5
6
1

3.3V supervisor

R221 10K
R224 10K
R222 10K

R211
R212
R213
R214
R215

JTAG debug port

[11] ARM_POWER_ON_RESET

GND

C200
100nF

+3.3V

ARM_WAKEUP

+3.3V
GND

R206
R205

+2.5V

GND

CO200_1 CO200_2 CO200_3 CO200_4


100nF
10nF
100nF
10nF

GND

+2.5V

IRQs

BOOTSEL0/PE0
BOOTSEL1/PE1
CLKSEL/PE2

LEDFLSH/PD0
PD1
PD2
PD3
PD4
PD5

PB0
PB1
PB2
PB3
PB4
PB5
PB6
PB7

PA0
PA1
PA2
PA3
PA4
PA5
PA6
PA7

PWM_DRIVE0
PWM_DRIVE1
FB0
FB1

SCLK/PCMCLK/SSICLK
SDOUT/PCMOUT/SSITXDA
SDIN/PCMIN/SSIRXDA
LRCK/PCMSYNC/SSITXFR
MCLKIN/SSIRXFR
MCLKOUT/BUZ

ADCOUT
ADCIN
ADCCS
ADCCLK
SMPCLK

EXTFIQ
EINT1
EINT2
EINT3

GND

GND

CO203
100nF

+5V

R231
1K

R227
1K

+3.3V

CO204
100nF

CO205
100nF

ARM_PORn [3]
LCD_RESET [12]

U200A
EP7312
Main1

47
46
45

62
61
60
59
56
55

20
19
18
17
16
15
14
13

30
29
28
27
26
25
24
23

76
75
82
80

63
66
67
65
68
93

78
69
70
77
79

44
43
42
41

10K

R204
R201
R207
R202

GND

GND

GND

GND

+5V

1
2
3

1
2
3

A0
A1
A2

A0
A1
A2

+5V

+5V

GND

OE

U204
FM24C64

R220
100R

TECHNOLOGIES BV
PO BOX 20 9200 AA DRACHTEN
DE TIJEN 3 DRACHTEN THE NETHERLANDS
TEL: +31 512 589 300 / FAX: +31 512 589 399

FRAM_WP

FRAM_I2C_SCL

5
6

The information contained herein is the


property of Neopost Technologies BV,
Drachten, the Netherlands. Any copying
or reproduction of this document in any
form and/or disclosure to other parties
without the express written consent of
Neopost Technologies BV is strictly
prohibited.

GND

WP

SCL

SDA

FRAM2_WP

R228
2K2

FRAM_I2C_SDA

U205
FM24C64

WP

SCL

SDA

R229
2K2
5

+5V

OUT

U202

GND

ARM_CORE_CLK
ARM_RTC_CLK
ARM_WAKEUP

+3.3V

TCK
TMS
TDI
TDO

SYSCLK

F3686KHZ
F32KHZ
F1024HZ

INT

CS
RD
WR
RESET

A1
A2
A3
A4

D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15

J201

[6] FV_DongleCommunication

HEADER 8X1

1
2
3
4
5
6
7
8

FRAM_I2C_SDA
FRAM_I2C_SCL
DBG5

U201
LC4256V-75T100

3
4
5

8
9
10
11
6
35
36
37

R226
1K

+5V

+5V

NM

GND
R230
56R

DBG5

TP205
DBG5

J202
UCAN CLIP

D105
BAT54S

Dongle

FV_PWM_Collator [8]
IN_FINGER_SOL [6]
IN_EJECT_SOL [6]

StackerSDA [9]
StackerCLK [9]
IN_SEALING_BRUSH_SOL [6]
StackerPresent [9]

FV_DongleCommunication [6]

FV_DigClutch_FE1 [9]
FV_DigClutch_FE2 [9]
FV_DigClutch_FE3 [9]
FV_CollatorStopPosDir [8]
FV_DigClutch_FoReverse [6]
FV_DigClutch_FoForward [6]
FV_DigClutch_FO1 [7]
FV_DigClutch_FO2 [7]
FV_DIR_Collator [8]
FV_MaxiFeeder_motor [8]
IN_MOTOR_RELAY [1]
IN_RPM_ENV_TRACK [6]
IN_SEALING_SOL [6]
FV_CollatorStopPosMotor [8]
IN_START_RELAY [1]

48
49
50
53
54
55
56
58
59
60
61
64
65
66
67
69

Otto Tuil

CPU CORE
Code:

time: 11:49:22

2825900V
Modified: Wednesday, August 20, 2008

Drawn:

GND

C201

+3.3V

FRAM_WP

WATER_LOW [6]
RESERVOIR_DET [6]

MAIN_PDISC [5]
FV_PDisc_Collator [8]
FV_DIG_FCEL_FE1 [9]
FV_DIG_FCEL_FE2 [9]
FV_DIG_FCEL_FE3 [9]
FV_ColStopPos1 [8]
FV_DIG_FCEL_COLL [7]
FV_DIG_FCEL_RH [10]
FV_DIG_FCEL_FO [7]
FV_SwitchMaxiFeeder [8]
FV_CurveDisc_FT1 [7]
FV_CurveDisc_FT2 [7]
IN_DIG_FCEL_CLOSER [6]
IN_DIG_FCEL_ENV_TRACK [5]
POWER_DOWN [1]
FV_ColStopPos2 [8]

62
77

12
14
15
16
17
19
20
21
22
23
27
28
29
30
31
34

CPLD
In circuit
programming
connection

PWM0
PWM1
PWM2

PD0
PD1
PD2
PD3
PD4
PD5
PD6
PD7

PC0
PC1
PC2
PC3
PC4
PC5
PC6
PC7
PC8
PC9
PC10
PC11
PC12
PC13
PC14
PC15

PB0
PB1

CAP0/INT0/PA0
CAP1/INT1/PA1
INT2/PA2
INT3/PA3
PA4
PA5
PA6
PA7
PA8
PA9
PA10
PA11
PA12
PA13
PA14
PA15

GPIO CPLD

GND

Size

A3

Sheet 2

of 12

01

Rev:

Andromeda A1/DS-70 mainboard

10nF

GND

GND

Title:

24
52
2
74

89

44
43
42

41

88
38
39
47

[3]
nCS2
[3,10,11,12] nRD
[3,11,12]
nWR
[3]
ARM_PORn

78
79
80
81
84
85
86
87
91
92
93
94
97
98
99
100
70
71
72
73

BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7
BD8
BD9
BD10
BD11
BD12
BD13
BD14
BD15

A1
A2
A3
A4

OSC. 14.7456Mhz

A[0..27]

+3.3V

[3,12]

[3,10,11,12] BD[0..15]

2X8 Kbyte FRAM

FV_ReadHead_S2 [10]
FV_ReadHead_S3 [10]

IN_TOP_COVER [1]
IN_SIDE_COVER [1]
IN_COLLATOR_COVER [1]
IN_RPM_STACKER [6]
LCD_ENABLE [12]
SI62_LCD_CD [12]
SI62_LCD_OE [12]
SPI_MPLEX_CS2 [12]
ADC_MUL[0..5] [4]

RH_ADC_START [10]
HCF_DETECT [9]
FV_ReadHead_S0 [10]
FV_ReadHead_S1 [10]

SPI1_ADC_CS [4]
SPI1_DAC_CS [4]
SPI_MPLEX_CS1 [12]

10K
10K
10K
32bits BOOTMEM

ADC_MUL0
ADC_MUL1
ADC_MUL2
ADC_MUL3
ADC_MUL4
ADC_MUL5

R216
R218
R217

GND

TP200
WINDOW

10K
10K
10K
10K

R232

SPI1_CLK [4,12]

SPI1_DAC_DAT [4,12]
SPI1_ADC_DAT [4,12]

R244
10K

+3.3V

R243
10K

+3.3V

R242
10K

+3.3V

CO200_5 CO200_6 CO200_7 CO200_8 CO200_9 CO200_10 CO200_11 CO200_12 CO200_13 CO200_14 CO200_15
100nF
10nF
100nF
10nF
100nF
10nF
100nF
10nF
100nF
10nF
100nF

+3.3V

ARM CORE

CO201_1 CO201_2 CO201_3 CO201_4 CO201_5 CO201_6 CO201_7 CO201_8 CO201_9 CO201_10 CO202
100nF
10nF
100nF
10nF
100nF
10nF
100nF
10nF
100nF
10nF
10nF

+3.3V

TXD2
RXD2

[11]
USB_RXF#
[11] USB_HOST_CON
[11]
USB_TXE#
[11]
TXD1
[11]
RXD1

[11]
[11]

[11] ARM_BOOT_MODE

[3]

+3.3V

R203
10K

+3.3V

10K

R200

7
8
4

50
49

470R

R241

ARM_RTC_CLK

158
159

470R

R240

ARM_CORE_CLK

+3.3V

2
21
57
74
89
107
123
139
167
183
197
72
181
51
157

VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDCORE
VDDCORE
VDDRTC
VDDOSC

VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSCORE
VSSCORE
VSSRTC
VSSOSC

VCC

GND

8
VCC
GND
4
8
VCC

Test Interface
GND

Serial I/O
4

SSI2 DAI Codec

3
12
33
64
73
81
98
108
116
124
140
149
168
174
182
190
198
203
71
180
48
160

4
VDD
GND
2

13
25
33
40
45
63
75
83
90
95
VCC
VCC
VCC
VCC
VCC
VCC
VCC
VCC
VCC
VCC
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND

Reset, Clock, and Power Controller


1
7
18
26
32
46
51
57
68
76
82
96

General Purpose I/O

PWM

10-20
SSI1 ADC
1

075.1
Service Manual

Main board - CPU core (2825900V)

rev. 1.0 - 12/2009

[12]
nCS4
[12]
nCS5
[2,10,11,12] nRD

GND

CO303
10nF

COL0
COL1
COL2
COL3
COL4
COL5
COL6
COL7

CL1
CL2
DD0
DD1
DD2
DD3
FRM
M

11
10
9

GND

CO304
10nF

+3.3V

12

U304A
74LCX11

R320

1
2
13

92
91
88
87
86
85
84
83

185
184
192
191
189
188
186
187

D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
D17
D18
D19
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31

Keyscan Interface

GND 10K

R310
470R

R300
470R

[11]
nCS1
[2]
nCS2
[10,12] nCS3

GND

D301
RED

TP301
TST2

D300
GREEN

TP300
TST1

LCD_CL1
LCD_CL2
LCD_DD0
LCD_DD1
LCD_DD2
LCD_DD3
LCD_FRM

179
177
175
172
170
166
164
150
147
145
143
141
137
135
133
131
129
127
122
120
118
115
113
111
109
104
102
100
97
96
95
94

CO305
10nF

74LCX11

U304C

3
4
5

U304B
74LCX11

D[0..31]

SDQM2
SDQM3

A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23
A24
A25
A26
A27

nCS0

U305A
74LVC32

204
205
206
207
208
1
105
5

202
6
201

200
199
54
53
196
195
194
193

178
176
173
171
169
165
163
148
146
144
142
138
136
134
132
130
128
126
121
119
117
114
112
110
106
103
101
99

CO306
10nF

U200B
EP7312

CS0
CS1
CS2
CS3
CS4
CS5
HALFWORD
WORD

MOE/SDCAS
WRITE/SDRAS
MWE/SDWE

SDCLK
SDCKE
PD6/SDQM0
PD7/SDQM1
SDQM2
SDQM3
SDCS0
SDCS1

A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
BA1/A13
BA0/A14
DRA12/A15
DRA11/A16
DRA10/A17
DRA9/A18
DRA8/A19
DRA7/A20
DRA6/A21
DRA5/A22
DRA4/A23
DRA3/A24
DRA2/A25
DRA1/A26
DRA0/A27

ARM CORE

GND

R315
470R

D8
D9
D10
D11
D12
D13
D14
D15

GND

R314
470R

D0
D1
D2
D3
D4
D5
D6
D7

23
24
25
26
29
30
31
32
33
34
22
35
36
20
21

[2,10,11,12]
[2,11,12]
[11]
[2]
[10,12]
[12]
[12]
GND

GND
GND
GND

VSSQ
VSSQ
VSSQ
VSSQ

CS
CAS
RAS
WE

CLK
CKE
DQML
DQMH

A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
NC/A12
BA0
BA1

1
19

2
3
4
5
6
7
8
9

1
19

2
3
4
5
6
7
8
9

GND

DIR
OE

A1
A2
A3
A4
A5
A6
A7
A8

B1
B2
B3
B4
B5
B6
B7
B8

18
17
16
15
14
13
12
11

18
17
16
15
14
13
12
11

U306
74LVC245

B1
B2
B3
B4
B5
B6
B7
B8

U303
74LVC245

+3.3V

GND

DIR
OE

A1
A2
A3
A4
A5
A6
A7
A8

+3.3V

VCC
VCC
VCC

VCCQ
VCCQ
VCCQ
VCCQ

DQ0
DQ1
DQ2
DQ3
DQ4
DQ5
DQ6
DQ7
DQ8
DQ9
DQ10
DQ11
DQ12
DQ13
DQ14
DQ15

MT48LC4M16/SO
or IS42S16400B-7T

28
41
54

6
12
46
52

19
17
18
16

SDCLK
SDCKE
SDQM0
SDQM1
nSDCS0
nRD
nSDRAS
nWR

38
37
15
39

A27
A26
A25
A24
A23
A22
A21
A20
A19
A18
A17
A16
A15
A14
A13

U300

BD8
BD9
BD10
BD11
BD12
BD13
BD14
BD15

BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7

27
14
1

49
43
9
3

2
4
5
7
8
10
11
13
42
44
45
47
48
50
51
53

BD[0..15]

+3.3V

D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15

SDRAM LS-WORD

DATABUS buffer

nRD
nWR
nCS1
nCS2
nCS3
nCS4
nCS5

R311 1R
Place near EP7312

A[0..27]

[2,10,11,12]

GND
GND
GND

VSSQ
VSSQ
VSSQ
VSSQ

CS
CAS
RAS
WE

CLK
CKE
DQML
DQMH

A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
NC/A12
BA0
BA1

VCC
VCC
VCC

VCCQ
VCCQ
VCCQ
VCCQ

DQ0
DQ1
DQ2
DQ3
DQ4
DQ5
DQ6
DQ7
DQ8
DQ9
DQ10
DQ11
DQ12
DQ13
DQ14
DQ15

27
14
1

49
43
9
3

2
4
5
7
8
10
11
13
42
44
45
47
48
50
51
53

+3.3V

D16
D17
D18
D19
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31

GND

The information contained herein is the


property of Neopost Technologies BV,
Drachten, the Netherlands. Any copying
or reproduction of this document in any
form and/or disclosure to other parties
without the express written consent of
Neopost Technologies BV is strictly
prohibited.

C300
33pF
NM

R312
10K
NM

SDCLK

[2]

25
24
23
22
21
20
19
18
8
7
6
5
4
3
2
1
48
17
16
9
10
13

100nF

GND

14

47

12

15

29
31
33
35
38
40
42
44
30
32
34
36
39
41
43
45

CO301_2

10nF

CO300_2

10nF

CO302_2

470R

R330

U302
S29AL016D

WP/ACC

BYTE

RESET

RY/BY

DQ0
DQ1
DQ2
DQ3
DQ4
DQ5
DQ6
DQ7
DQ8
DQ9
DQ10
DQ11
DQ12
DQ13
DQ14
DQ15

10nF

CO301_4

10nF

CO300_4

10nF

CO308_2

100nF

CO301_5

100nF

CO300_5

R305 10K
R306 10K

+3.3V

25
24
23
22
21
20
19
18
8
7
6
5
4
3
2
1
48
17
16
9
10
13
nRD 28
nCS0 26
nWR 11

A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23

Otto Tuil

CPU Memory
Code:

10nF

CO301_6

10nF

14

47

12

15

29
31
33
35
38
40
42
44
30
32
34
36
39
41
43
45

D16
D17
D18
D19
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31

100nF

CO301_7

100nF

CO300_7

U308
S29AL016D

WP/ACC

BYTE

RESET

RY/BY

DQ0
DQ1
DQ2
DQ3
DQ4
DQ5
DQ6
DQ7
DQ8
DQ9
DQ10
DQ11
DQ12
DQ13
DQ14
DQ15

CO300_6

GND

OE
CE
WE

A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
NC

+3.3V

time: 11:49:22

2825900V
Modified: Wednesday, August 20, 2008

Drawn:

100nF

CO301_3

100nF

CO300_3

100nF

CO308_1

D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15

[2,12]

FLASHROM MS-WORD

A[0..27]

10nF

CO301_8

10nF

D303
RED
FLASH
WRITE

R304
470R

CO300_8

+3.3V

Size

A3

Sheet 3

of 12

01

Rev:

Andromeda A1/DS-70 mainboard

100nF

Title:

10nF

CO301_1

+3.3V

GND

100nF

CO300_1

+3.3V

GND

GND

OE
CE
WE

A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
NC

CO302_1

+3.3V

ARM_PORn

nRD 28
nCS0 26
nWR 11

A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23

+3.3V

FLASHROM LS-WORD

TECHNOLOGIES BV
PO BOX 20 9200 AA DRACHTEN
DE TIJEN 3 DRACHTEN THE NETHERLANDS
TEL: +31 512 589 300 / FAX: +31 512 589 399

C301
33pF
NM

R313
10K
NM

Place termination networks


near SDRAM

MT48LC4M16/SO
or IS42S16400B-7T

28
41
54

6
12
46
52

19
17
18
16

38
37
15
39

23
24
25
26
29
30
31
32
33
34
22
35
36
20
21

U301

SDRAM MS-WORD

GND

nSDCS0
nRD
nSDRAS
nWR

SDCLK
SDCKE
SDQM2
SDQM3

A27
A26
A25
A24
A23
A22
A21
A20
A19
A18
A17
A16
A15
A14
A13

Vcc

37
Vss
27

Vcc

37
Vss

D[0..31]

Vss
46

[12]
[12]
[12]
[12]
[12]
[12]
[12]

D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
D17
D18
D19
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31

20
VCC
GND
10
20

Static Memory IF
VCC

LCD Interface

GND

Vss

rev. 1.0 - 12/2009

SDRAM Interface

27

Data Bus
46

Address Bus
10

Service Manual
075.1

Main board - CPU memory (2825900V)

10-21

SPI1_ADC_CS
SPI1_ADC_DAT
SPI1_CLK
SPI1_DAC_DAT
SPI1_DAC_CS

[9] FV_OFFSET_FE1
[9] FV_OFFSET_FE2
[9] FV_OFFSET_FE3

[2]
[2,12]
[2,12]
[2,12]
[2]

CO406
100nF

REF

DIN
CS
SCLK
DOUT

LDAC

C402
100nF

3.98V

13
11
12
14

GND

DAC-A
DAC-B
DAC-C
DAC-D
DAC-E
DAC-F
DAC-G
DAC-H

U403
MAX5258

GND

GND

CO401
10nF

+5V

GND

R426
39K

R423
10K

+5V

CO405
100nF

REF

CO402
10nF

C403
100nF

GND

CO404
10nF

DIN
CS
SCLK
DOUT

LDAC

3.98V

13
11
12
14

DAC-A
DAC-B
DAC-C
DAC-D
DAC-E
DAC-F
DAC-G
DAC-H

+5V

6
5

8
9
10
11
12
13
14
15

0
1
2
3
4
5
6
7

7
U406B
LM358

D402
BAT54S
Chan
2
Chan
1
16 Chan
15 Chan
Chan
7
Chan
8
Chan
9
10 Chan

+5V

D401
BAT54S
Chan
2
Chan
1
16 Chan
15 Chan
Chan
7
Chan
8
Chan
9
10 Chan

GND

R438
1K

U405
MAX5258

Photocel DAC2

GND

R413
39K

R410
10K

+5V

CO403
100nF

Photocel DAC1

GND

R460
10K

VDD

GND

VDD

GND

GND

R404
10K

R403
4K7

GND

R432
1K

R430
1K

R428
1K

R425
1K

R422
1K

R420
1K

R418
1K

R416
1K

R411
1K

R408
1K

R406
1K

CO400_1
10nF

1
6
7
CS
DOUT
CLK

GND

CO400_3
1uF

R401
56R

GND

U400
LTC1197

+IN
VREF
-IN

R402
56R

GND

R433
1R

R434
1R

R437
4K7

R431
82R

R429
82R

R427
82R

R424
82R

R421
82R

R419
82R

R417
82R

R415
82R

R409
82R

R407
82R

R405
82R

+5V

-12V

IN_TX_CLOSER [6]

IN_TX_EXIT [5]

IN_TX_LOC [6]

IN_TX_FLAP [5]

IN_TX_ENV_TRACK [5]

FV_TX_Folder [7]

FV_TX_ReadHead [7]

FV_TX_Collator [8]

C404
10nF

R435
100K

The information contained herein is the


property of Neopost Technologies BV,
Drachten, the Netherlands. Any copying
or reproduction of this document in any
form and/or disclosure to other parties
without the express written consent of
Neopost Technologies BV is strictly
prohibited.

GND

INH

13
14
15
12
1
5
2
4

Title:

U401
74HCT4051

X0
X1
X2
X3
X4
X5
X6
X7

TECHNOLOGIES BV
PO BOX 20 9200 AA DRACHTEN
DE TIJEN 3 DRACHTEN THE NETHERLANDS
TEL: +31 512 589 300 / FAX: +31 512 589 399

Uout = 11 x I photocell

Current measurement
1

U406A
LM358

Q411
BC817

Q410
BC817

Q409
BC817

Q408
BC817

Q407
BC817

Q406
BC817

Q405
BC817

Q404
BC817

Q402
BC817

FV_TX_Feeder3 [9]

FV_TX_Feeder2 [9]

FV_TX_Feeder1 [9]

ADC_MUL3
ADC_MUL4
ADC_MUL5

R450
1K

A
B
C

GND

GND

R452
1K

R451
1K

11
10
9

11
10
9

A
B
C

GND

INH

A
B
C

+5V

GND

13
14
15
12
1
5
2
4

R440
2K2

U404
74HCT4051

X0
X1
X2
X3
X4
X5
X6
X7

Otto Tuil

ANALOG I/O
Code:

Chan
Chan
Chan
Chan
Chan
Chan
Chan
Chan

Chan
Chan
Chan
Chan
Chan
Chan
Chan
Chan

14
15
16
17
18
19
20
21

6
7
8
9
10
11
12
13

0
1
2
3
4
5

time: 11:49:22

2825900V
Modified: Wednesday August 20 2008

Drawn:

INH

13
14
15
12
1
5
2
4

U402
74HCT4051

X0
X1
X2
X3
X4
X5
X6
X7

Chan
Chan
Chan
Chan
Chan
Chan

IN_ANA_RX_FLAP [5]
IN_ANA_RX_EXIT [5]
IN_ANA_RX_LOC [5]
IN_ANA_RX_CLOSER [6]
MAIN_CURRENT [1]
FV_MaxiFeeder23Detect [8]

FV_ANA_RX_Collator [7]
FV_ANA_RX_ReadHead [10]
FV_ANA_RX_Folder [7]
IN_ANA_RX_ENV [5]

FV_ANA_RX_Feeder1 [9]
FV_ANA_RX_Feeder2 [9]
FV_ANA_RX_Feeder3 [9]

FV_ReadHead_ANA0 [10]
FV_ReadHead_ANA2 [10]

FV_DFC_FE1 [9]
FV_DFC_FE2 [9]
FV_DFC_FE3 [9]

GND

D400
BAT54S

+2.5V

Size

A3

Sheet 4

of 12

01

Rev:

Andromeda A1/DS-70 mainboard

+5V

GND

C400
100nF

2,5 Volt

GND

11
10
9

Analog multiplexer

GND

2
5
3

AVREF

ADC_MUL0
ADC_MUL1
ADC_MUL2

+5V

Q401
BC817

R436
4K7

3
Q400
BC817

3 +

GND

Current Sink

GND

CO400_2
100F

R400
56R

+5V

8
VCC
GND
4

16
VCC
GND
8

10 bit ADC

1
1
1
1
1
1
1
1
1

GND
8

1
1

16
VCC
GND
8
VCC

16

[2] ADC_MUL[0..5]

10-22

GND

075.1
Service Manual

Main board - analog I/O (2825900V)

rev. 1.0 - 12/2009

GND

+5V

CO500
100nF

JST5

GND

VCC_OUT

VCC_OUT

VCC_OUT

VCC_OUT

VCC_OUT

GND

CO502
10nF

+3.3V

VCC_OUT

CO501
10nF

+3.3V

EXIT RX

EXIT TX

J502

1
2
3
4
5

JST11

1
2
3
4
5
6
7
8
9
10
11

J500

Exit
photocell

LOC RX

FLAP RX

FLAP TX

ENV_TRACK RX

ENV_TRACK TX

Enveloppe
Track
photocells

GND

R521
1K

U500B
LM358

IN_TX_EXIT [4]

IN_TX_FLAP [4]

IN_TX_ENV_TRACK [4]

+
+
GND

1K

R520
13

TP503
EXIT
NM

R515
8K2

dist: 69mm

R513
4K7

TP502
LOC
NM

GND

R511
470R

dist: 56mm

R522
470R

TP501
FLAP
NM

GND

GND

74LVC14

U502F
12

3.3

GND

R514
10K

GND

R512
10K

3 +

R510
10K

R509
1K

+5V

GND

R500
10K

R506
8K2

TP500
ENV
NM

R501
2K2

C502
1nF

dist: 9mm

R508
1K

dist: 27mm

8
4

rev. 1.0 - 12/2009

C505
10nF

C504
10nF

C503
10nF

U500A
LM358

R507
68K

C500
10nF

IN_ANA_RX_EXIT [4]

IN_ANA_RX_LOC [4]

IN_ANA_RX_FLAP [4]

[2]

The information contained herein is the


property of Neopost Technologies BV,
Drachten, the Netherlands. Any copying
or reproduction of this document in any
form and/or disclosure to other parties
without the express written consent of
Neopost Technologies BV is strictly
prohibited.

IN_DIG_FCEL_ENV_TRACK

IN_ANA_RX_ENV [4]

MAIN_PDISC

TECHNOLOGIES BV
PO BOX 20 9200 AA DRACHTEN
DE TIJEN 3 DRACHTEN THE NETHERLANDS
TEL: +31 512 589 300 / FAX: +31 512 589 399

[2]

GND

C501
33pF

U502A
74LVC14
2 3.3 1
R505
10K

R503
4K7

+3.3V

R504
150R

GND

VCC_OUT

JST5

1
2
3
4
5

J501

Main
PulsDisc

Otto Tuil

Code:

time: 11:49:22

2825900V

INSERTER PHOTOCELLS

Size

A3

Sheet 5

of 12

01

Rev:

Andromeda A1/DS-70 mainboard

NM

TP505
PDSC

Modified: Wednesday, August 20, 2008

Drawn:

+3.3V
R502
470R
D500
GREEN

Title:

Service Manual
075.1

Main board - Inserter photocells (2825900V)

10-23

CO600
10nF

GND

+5V

1
2
3
4
5
6

1
2
3
4
5
6
7
8

JST8

J603

JST6

J601

JST10

1
2
3
4
5
6
7
8
9
10

J600

CO601
10nF

CO605
100nF

Data
Gnd

JST2

1
2

J650

Electronic
ID tag

Sealing brush sol

TX closer

TX loc-cel

Eject solenoid

LOC_A1

TX closer

TX loc-cel

Eject solenoid

LOC

finger sol.

RPM FoForward

RPM FoReverse

RPM stracker

RPM env. track

GND

24V

24V

O1
O2
O3
O4
O5
O6
O7

R650
56R

C650
33pF

GND

I1
I2
I3
I4
I5
I6
I7

D600
12V

GND

1
2
3
4
5
6
7

GND

R600
56R

24V

Q600B
SI4946EY

D605
STPS340U

Q601A
SI4946EY

24V

GND

GND

R607
56R

U601A
74HCT14_5
5 1

GND

R620
1K

U600F
74HCT14_5
12
5 13

U600E
74HCT14_5
10
5 11

U600D
9 74HCT14_5

U600C
5 74HCT14_5

R608
56R

C608
10nF
GND

GND

C606
10nF

R631
150R

U600B
3 74HCT14_5

Q630
BC817

GND

D603
STPS340U

C603
220F

U600A
1 74HCT14_5

R630
10K

GND

C600
100nF

C602
10nF

U602
ULN2003L

24V

GND

GND

VCC_OUT

VCC_OUT

Q600A
SI4946EY

D601
STPS340U

16
15
14
13
12
11
10

COM

GND

Rear
side
actuators

7
8

7
U605B
LM358

[2]

FV_DongleCommunication [2]

IN_SEALING_BRUSH_SOL [2]

IN_TX_CLOSER [4]

IN_TX_LOC [4]

IN_EJECT_SOL [2]

IN_FINGER_SOL [2]

FV_DigClutch_FoForward [2]

FV_DigClutch_FoReverse

IN_RPM_STACKER [2]

IN_RPM_ENV_TRACK [2]

The information contained herein is the


property of Neopost Technologies BV,
Drachten, the Netherlands. Any copying
or reproduction of this document in any
form and/or disclosure to other parties
without the express written consent of
Neopost Technologies BV is strictly
prohibited.

TECHNOLOGIES BV
PO BOX 20 9200 AA DRACHTEN
DE TIJEN 3 DRACHTEN THE NETHERLANDS
TEL: +31 512 589 300 / FAX: +31 512 589 399

[2] RESERVOIR_DET

[2] WATER_LOW

[2] IN_SEALING_SOL

[2] IN_DIG_FCEL_CLOSER

[4] IN_ANA_RX_CLOSER

+5V

+
-

GND

C609 100nF
C610 100nF

R613
10K

R612
10K

Q601B
SI4946EY

D604
STPS340U
VCC_OUT

GND

R610 10K
R611 10K

+3.3V

24V

JST4

1
2
3
4

J604

JST4

1
2
3
4

J602

WATER
LEVEL

CLOSER

Sealing solenoid

RX closer

Otto Tuil

Code:

INSERTER POWER I/O

time: 11:49:22

2825900V

Size

A3

Sheet 6

of 12

01

Rev:

Andromeda A1/DS-70 mainboard

R609
56R

R605
1K

C604
1nF

R615
8K2

dist: 33mm

24V

GND

GND

C607
10nF

GND

R604
8K2

R606
1K

GND

R602
8K2

TP600
CLOSER
NM

Modified: Wednesday, August 20, 2008

Drawn:

R601
10K

GND

U605A
LM358

R603
68K

C601
10nF

U601B
74HCT14_5
3 5
4

Title:

8
4

24V

1
2

7
8

1
1
2

5
6

1
2
6
5

24V

+
+

10-24
3

075.1
Service Manual

Main board - Inserter power I/O (2825900V)

rev. 1.0 - 12/2009

Clutch FT2

Clutch FT1

Slotted switch FT2

RX Reading head

Slotted switch FT1

JST12

1
2
3
4
5
6
7
8
9
10
11
12

J700

FOLDERS
IN KAP

GND

VCC_OUT

GND

+5V

CO701
100nF

24V

16
15
14
13
12
11
10

R710
4K7

+3.3V

R700
4K7

+3.3V

O1
O2
O3
O4
O5
O6
O7

U502C
74LVC14
6
3.3

1
2
3
4
5
6
7

GND

C702
33pF

GND

10

U601E
74HCT14_5
5 11

D702
GREEN
FT2

R709
470R

+3.3V

D701
GREEN
FT1

R701
470R

+3.3V

U601D
74HCT14_5
8
5 9

C704
100nF

U502D
74LVC14
9 3.3 8

U700
ULN2003L

I1
I2
I3
I4
I5
I6
I7

5
C700
33pF

D700
12V

24V

GND

GND

GND

R711
1K

R702
1K

COM

GND

[2]

[2]

FV_DigClutch_FO2 [2]

FV_DigClutch_FO1 [2]

FV_CurveDisc_FT2

FV_RX_ReadHead [10]

FV_CurveDisc_FT1

The information contained herein is the


property of Neopost Technologies BV,
Drachten, the Netherlands. Any copying
or reproduction of this document in any
form and/or disclosure to other parties
without the express written consent of
Neopost Technologies BV is strictly
prohibited.

[4] FV_ANA_RX_Folder

[2] FV_DIG_FCEL_FO

[4] FV_ANA_RX_Collator

[2] FV_DIG_FCEL_COLL

+5V

GND

GND

R715
1K

+5V

GND

R706
1K

+
-

+5V

R712
8K2

R704
8K2

TECHNOLOGIES BV
PO BOX 20 9200 AA DRACHTEN
DE TIJEN 3 DRACHTEN THE NETHERLANDS
TEL: +31 512 589 300 / FAX: +31 512 589 399

U701B
LM358

R713
68K

U701A
LM358

R703
68K
8

rev. 1.0 - 12/2009


4

NM

TP701
FO

GND
[4] FV_TX_Folder

dist: 45mm

R717
470R

R716
150R

[4] FV_TX_ReadHead

dist: 12mm

GND

R750
1K

R707
2K2

NM

TP700
COLL

VCC_OUT

JST8

1
2
3
4
5
6
7
8

J701

TX Read head

RX Folder

TX Folder

RX Collator

Photocells
collator
side

Code:

time: 11:49:22

2825900V
Modified: Wednesday, August 20, 2008

Otto Tuil

Feeder Vertical FOLDER

Size

A3

Sheet 7

of 12

01

Rev:

Andromeda A1/DS-70 mainboard

R714
10K

C703
10nF

Drawn:

Title:

GND

GND

C701
10nF

R705
10K

Service Manual
075.1

Main board - Feeder vertical folder (2825900V)

10-25

CO804
100nF

[2] FV_MaxiFeeder_motor

[4] FV_MaxiFeeder23Detect

[2] FV_SwitchMaxiFeeder

GND

[2] FV_DIR_Collator

GND

CO805
100nF

+3.3V

U804C
74HCT14_5
5 5
6

[2] FV_PWM_Collator

[2] FV_PDisc_Collator

U804D
74HCT14_5
9 5
8

D800
BAT54S

C801
100nF

U805A
74LVC14
2 3.3 1

U804B
74HCT14_5
4
5

[2] FV_CollatorStopPosMotor

[2] FV_CollatorStopPosDir

+5V

U804A
74HCT14_5
1 5
2

GND

R815
1K

U805F
74LVC14

GND

GND

R803
10K

+5V

IN1B
IN2B

IN2A
IN1A

VBOOT

GND

Q800B
SI4946EY

R802
10K

R804
10K

C803
100nF
GND

+5V

VCP

R801
10K

+3.3V

14
15

7
6

17

C802
100nF
GND
C804
10nF

C806
100nF

R800
10K

GND

R806
100R

C800
100nF
GND

GND

C805
100nF

24V

1
2

[2] FV_ColStopPos2

6
5

+5V

GND

EN_A
Cooling plate

21

5
1
10
11
20

16
EN_B
PGND1
PGND2
PGND3
PGND4

R805
10K

24V

2
19

12

GND

13

R808
470R

+3.3V

L800
744272332

L801
744272332

U805B
74LVC14
3.3 3

3.3

10

R809
4K7

+3.3V

GND

C830
1nF

U905E
74HCT14_5

D810
STPS340U

R807
150R

TX Collator

- Collator motor
+

Pdisc collator

MF 2,3 detect

Switch MF

Motor MF

MAXI
FEEDERS

JST6

1
2
3
4
5
6

Paperstop mtr +
Paperstop mtr 1

Collator
Unit

JST10

1
2
3
4
5
6
7
8
9
10

J801

JST8

Paperstop SlottedSwitch 2

Paperstop SlottedSwitch 1

Collator
Paper-stop

Otto Tuil

Code:

time: 11:49:22

2825900V

Feeder Vertical COLLATOR

Size

A3

Sheet 8

of 12

01

Rev:

Andromeda A1/DS-70 mainboard

GND

Q800A
SI4946EY

GND

GND

VCC_OUT

GND

1
2
3
4
5
6
7
8

J802

J800

VCC_OUT

R830
4K7

+3.3V

Modified: Wednesday August 20 2008

Drawn:

Title:

GND

C810
10nF

24V

[4] FV_TX_Collator

R811
56R

GND

C831
1nF

1K

R832

R831
4K7

+3.3V

1K

R833

TECHNOLOGIES BV
PO BOX 20 9200 AA DRACHTEN
DE TIJEN 3 DRACHTEN THE NETHERLANDS
TEL: +31 512 589 300 / FAX: +31 512 589 399

11

R810
1K

3.3

C807
33pF
GND

U805D
74LVC14

U805C
74LVC14

The information contained herein is the


property of Neopost Technologies BV,
Drachten, the Netherlands. Any copying
or reproduction of this document in any
form and/or disclosure to other parties
without the express written consent of
Neopost Technologies BV is strictly
prohibited.

18

D801
GREEN
PD COLL.

TP800
PD COL

U800
L6205PD

SENB

SENA

OUT1B

OUT2B

OUT2A

OUT1A

VSa
VSb

[2] FV_ColStopPos1

12
13

3.3

1
2

8
7

10-26
1

075.1
Service Manual

Main board - Feeder vertical collator (2825900V)

rev. 1.0 - 12/2009

GND

JST10

1
2
3
4
5
6
7
8
9
10

J902

GND

24V

GND

CO901
100nF

+12V

GND

CO902
100nF

+12V

[2] FV_DigClutch_FE3

[2] FV_DigClutch_FE2

[2] FV_DigClutch_FE1

GND

GND

GND

C912
100nF

U905C
74HCT14_5
5 5
6

R947
39K

CO905
100nF

GND

GND

+5V

R943
5K6

R941
5K6

GND

R935
1K

R915
5K6

GND

R909
1K

GND

R914

C902

R960
1K

13

GND

C900
10nF

R906
10K

R940

C910

U905F
74HCT14_5
12
5

GND

+5V

1
2
3
4
5
6
7

GND

U901B
LM358

39K

100nF

GND

2
-

2
-

3 +

24V

GND

O1
O2
O3
O4
O5
O6
O7

16
15
14
13
12
11
10

D900
12V

GND

C904
100nF

GND

R951
4K7

R950
4K7

FV_DFC_FE2 [4]

FV_ANA_RX_Feeder2 [4]

FV_DIG_FCEL_FE2 [2]

FV_DFC_FE1 [4]

FV_ANA_RX_Feeder1 [4]

FV_DIG_FCEL_FE1 [2]

FV_Clutch_FE3

FV_Clutch_FE2

FV_Clutch_FE1

C913
100nF

TP906
DFC FE2

GND

R931
10K

GND

R948
1K

U904
ULN2003L

R944
1K

GND

R928
68K

U901A
LM358

+12V

GND

R904
10K

TP902
DFC FE1

R923
1K

U900A
LM358

R902
68K

GND

GND

R917
1K

R936
1K

I1
I2
I3
I4
I5
I6
I7

+12V

3 +

R910
1K

U900B
LM358

39K

100nF

R926
8K2

U905A
74HCT14_5
1 5
2

+5V
R900
8K2

C916
100nF

GND

C908
10nF

R929
10K

U905D
74HCT14_5
9 5
8

U905B
74HCT14_5
3 5
4

GND

R934
1K

NM

TP904
FE-2

C905
100nF

dist: 16mm

R921
39K

FV_TX_Feeder2 [4]

FV_Clutch_FE2

R916
5K6

GND

NM

TP900
FE-1

R908
1K

dist: 16mm

FV_TX_Feeder1 [4]

FV_Clutch_FE1

VCC_OUT

[4] FV_OFFSET_FE2

CO900
100nF

+12V

DFC feeder2

TX feeder-2

RX feeder-2

Clutch fe2

GND

[4] FV_OFFSET_FE1

JST10

1
2
3
4
5
6
7
8
9
10

Feeder-2

DFC feeder1

TX feeder-1

RX feeder-1

Clutch fe1

J901

VCC_OUT

8
4
8
4

ACC

R959
1K

GND

VCC

SCLin

SDAin

R919

C903

+5V

3.3

11

GND

C924
100nF

R957
10K

R958
10K

+3.3V

+5V

R922
5K6

GND

L900
L901

2K7
2K7

D902
BAT54S

R932
10K

+5V

GND

VCC_OUT

FV_Clutch_FE3

R933
10K

C922 33pF
C923 33pF

GND

GND

R956
10K

GND

R925
39K

GND

+5V

GND

C911
100nF

GND

D901
BAT54S

C907
100nF

R920
5K6

dist: 16mm

R913
1K

NM

TP901
FE-3

DFC feeder3

HCF Present

TX feeder-3

RX feeder-3

Clutch fe3

Feeder-3

JST10

1
2
3
4
5
6
7
8
9
10

J903

GND

C925
100nF

L902
2K7

JST5

1
2
3
4
5

J904

ACCESSORY
STACKER

GND

24V

Code:

time: 11:49:22

2825900V
Modified: Wednesday, August 20, 2008

Otto Tuil

Feeder Vertical FEEDERS

Size

A3

Sheet 9

of 12

01

Rev:

Andromeda A1/DS-70 mainboard

74LVC14

Drawn:

Title:

10

U502E

10nF

10nF
GND

+5V
CO906_2

GND

R912
1K

GND

R955
10K

CO906_1

SCLout

SDAout

VCC2

74LVC14

3.3

U502B

U902B
LM358

39K

100nF

R907
10K

C901
10nF

GND

R901
8K2

GND

+5V

U906
LTC4300A-2

+3.3V

+3.3V

GND

R924
1K

R918
1K

GND

R911
1K

+
-

TECHNOLOGIES BV
PO BOX 20 9200 AA DRACHTEN
DE TIJEN 3 DRACHTEN THE NETHERLANDS
TEL: +31 512 589 300 / FAX: +31 512 589 399

GND

R953 10K
R954 10K

GND

+12V

R930
1K

U902A
LM358

R903
68K

TP903
DFC FE3

R905
10K

C906
100nF

GND

R952
4K7

C920 33pF
C921 33pF

The information contained herein is the


property of Neopost Technologies BV,
Drachten, the Netherlands. Any copying
or reproduction of this document in any
form and/or disclosure to other parties
without the express written consent of
Neopost Technologies BV is strictly
prohibited.

[2] StackerPresent

[2] StackerCLK

[2] StackerSDA

[4] FV_DFC_FE3

[4] FV_OFFSET_FE3

[2] HCF_DETECT

[4] FV_TX_Feeder3

[4] FV_ANA_RX_Feeder3

[2] FV_DIG_FCEL_FE3

8
4

2
1

24V

+
+

Feeder-1

9
COM
GND
8

GND
4

2
1

rev. 1.0 - 12/2009


-

Service Manual
075.1

Main board - Feeder vertical feeders (2825900V)

10-27

MOLEX
Modular
jack

6
5
4
3
2
1

J1000

CASE

GND

+12V

R1032
1K

C1008
100nF

GND

R1004
4K7

R1000
4K7

GND

R1021
100K

R1018
100K

R1012
39K

LM358
U1003B

GND

-12V

R1001
4K7
1

U1000A
LM358

+12V

GND

C1000
1nF

-12V
C1001
1nF

-12V

Reading
Head

GND

GND

12

R1034
4K7

+5V

R1033
47K

R1006
47K

GND

CO1003
100nF

GND

CO1002
100nF

CO1004
100nF
GND

+5V

U1004C
HC4066

R1013
680K

-12V

R1007
100K
GND

GND

GND

+3.3V

U1004D
HC4066

CO1001
100nF
GND

+5V

GND

C1009
100nF

GND

R1005
4K7

+2.5V

D1000
BAT54S

U1000B
LM358

R1025
10K
GND

C1004
1nF

5 +

C1002
10nF

CO1000_2
100nF

-12V

R1024
10K

R1023
82R

C1005
1nF

+12V

R1022
56R

C1003
10nF

R1003
6k8

R1019
10K

CO1000_1
100nF

+5V

R1002
6K8

2
1

+5V

2
-

3 +

R1020
47K

R1011
100K

GND

U1004A
HC4066

R1014
680K

5 +
7

GND

TP1000
OMR_OUT

Rv=27K

R1017
47K

GND

R1026
8K2

+5V

GND

BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7

3 +

[2,3,11,12]
[3,12]

[2,3,11,12]

Otto Tuil

Code:

time: 11:49:22

2825900V

Feeder Vertical READING

Size

A3

Sheet 10 of 12

01

Rev:

FV_ANA_RX_ReadHead [4]

FV_DIG_FCEL_RH [2]

FV_ReadHead_S3 [2]

FV_ReadHead_S2 [2]

FV_ReadHead_ANA0 [4]

FV_ReadHead_DAC0 [12]

FV_ReadHead_ANA2 [4]

FV_ReadHead_DAC1 [12]

FV_ReadHead_S0 [2]

FV_ReadHead_S1 [2]

RH_ADC_START [2]

nRD
nCS3

BD[0..15]

U1003A
LM358

R1027
68K

R1040
10K

GND

R1031
1K

GND

+5V

U1002
AD7819

6
5

8
9
10
11
12
13
14
15

Modified: Wednesday, August 20, 2008

Drawn:

GND

C1010
10nF

R1028
10K

RD
CS

DB0
DB1
DB2
DB3
DB4
DB5
DB6
DB7

CONVST

GND

BUSY

Vref

Vin

+3.3V

Andromeda DS-70 mainboard

R1030
150R

R1029
150R

dist: 12mm

Title:

GND

TP1001
ReadHead

C1006
100nF

C1007
100nF

AVREF
2,5 Volt

GND

R1010
1K
GND

[7] FV_RX_ReadHead

GND

R1016
68K

R1008
470R

Fast readhead ADC

TECHNOLOGIES BV
PO BOX 20 9200 AA DRACHTEN
DE TIJEN 3 DRACHTEN THE NETHERLANDS
TEL: +31 512 589 300 / FAX: +31 512 589 399

U1004B
13 HC4066

R1015
47K

R1009
100K

U1001B
LM358

The information contained herein is the


property of Neopost Technologies BV,
Drachten, the Netherlands. Any copying
or reproduction of this document in any
form and/or disclosure to other parties
without the express written consent of
Neopost Technologies BV is strictly
prohibited.

U1001A
LM358

GND

10
11

2
1

9
8

3
4

16
VDD
GND
3

10-28
4

075.1
Service Manual

Main board - Feeder vertical reading (2825900V)

rev. 1.0 - 12/2009

GND

CO1102
100nF

+5V

HORUS
CONNECTION

JST12

1
2
3
4
5
6
7
8
9
10
11
12

J1102

CO1104
100nF

RXD2
TXD2

1
2
3

J1120

JST5

1
2
3
4
5

CON3

+3.3V
RXD1
TXD1

+24V

+5 Volt
DataData+
GND
SHIELD

J1100

GND

GND

CO1100_1
100nF

+5V

GND

GND

56R
56R
56R
56R

CO1100_2
100nF

R1123
R1121
R1122
R1120

+5V

[2] USB_HOST_CON

C1120
10nF

GND

+3.3V

GND

24V_IN

CASE
GND

GND

C1106
33pF

R1109
10K

GND

GND

C1105
33pF
NM

R1102
R1100
R1104
R1103

GND

C1130
10nF

+5V

T2OUT
R2IN
T1OUT
R1IN

GND

1
2
3
4

R1111
2K2

EECS
EESK
EEDATA

C1122
10nF

GND

GND

GND

33pF

C1108

GND

GND

CO1100_3
100nF

+3.3V

100nF

100nF

100nF

CO1101
100nF

C1112
100nF

1 C1109
3
4 C1110
5
2 C1111
6

10
9
11
12

U1104
MAX232ACSE

C+
C1C2+
C2V+
V-

T2IN
R2OUT
T1IN
R1OUT
+5V

47

48

44

43

8
7

CO1103
100nF

GND

+5V

GND

R1141
NM
10K

R1140
NM
10K

R1112
10K

R1125
10K

TEST

EEDATA

EESK

EECS

RESET

XTOUT

XTIN

RSTOUT

USB DM (-)
USB DP (+)

GND

R1113
4K7

100nF

C1101

R1101
470R

+3.3V

[2]
[2]

[2]
[2]

26
41

30
29
28
27

40
39
38
37
36
35
33
32

21
19
16
17

20

22

24
23

10
15
13
12
11

GND

R1131
4K7

+3.3V

R1127
1K

B1
B2
B3
B4
B5
B6
B7
B8

GND

1
19

2
3
4
5
6
7
8
9

BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7

nCS1

U1101B
74LVC32

GND

R1115
10K
GND

R1116
10K
GND

TECHNOLOGIES BV
PO BOX 20 9200 AA DRACHTEN
DE TIJEN 3 DRACHTEN THE NETHERLANDS
TEL: +31 512 589 300 / FAX: +31 512 589 399

R1114
10K

[2,3,12]

[3]

GND

11
R1128
1K

U1101C
74LVC32

12

U1101D
74LVC32

Otto Tuil

CPU USB I/O


Code:

time: 11:49:22

2825900V

Size

A3

Sheet 11 of 12

01

Rev:

Andromeda A1/DS-70 mainboard

BOARD_ID[0..3]

[3]
[2,3,10,12]

Modified: Wednesday, August 20, 2008

Drawn:

Title:

R1117
10K

BOARD_ID0
BOARD_ID1
BOARD_ID2
BOARD_ID3

nWR

nCS1

nRD

[2,3,10,12]
[3]

[2,3,10,12]

USB_RXF# [2]
USB_TXE# [2]

nRD
nCS1

BD[0..15]

ARM_POWER_ON_RESET [2]

[2]
[2]

ARM_BOOT_MODE [2]

RXD1
TXD1

R1151
4K7

+3.3V

U1101A
74LVC32

R1150
4K7

+3.3V

U1103
74LVC245

DIR
OE

A1
A2
A3
A4
A5
A6
A7
A8

U805E
74LVC14
10 3.3 11

18
17
16
15
14
13
12
11

R1152
4K7

+3.3V

+3.3V

BOARD_ID[0..3]

R1126
1K

R1133
4K7

+3.3V

HARDWARE IDENTIFICATION

+3.3V

BOARD_ID0
BOARD_ID1
BOARD_ID2
BOARD_ID3

The information contained herein is the


property of Neopost Technologies BV,
Drachten, the Netherlands. Any copying
or reproduction of this document in any
form and/or disclosure to other parties
without the express written consent of
Neopost Technologies BV is strictly
prohibited.

TXD2
RXD2

TXD1
RXD1

U1100
FT2232

SI/WUB
PWREN

RXF#
TXE#
RD
WR

FIFO D0
FIFO D1
FIFO D2
FIFO D3
FIFO D4
FIFO D5
FIFO D6
FIFO D7

CTS
DSR
RI
DCD

DTR

RTS

TXD
RXD

SI/WUA
TXDEN
SLEEP
RXLED
TXLED

+3.3V

13

USB Connectivity

3V3OUT

GND

R1124
4K7

GND

33pF

X1100
6,0MHz

C1107

R1130
470R

C1132
10nF
GND

R1105
1K

56R
56R
56R
56R

C1131
10nF

RS232 driver

CS
SK
DIN
DOUT

R1110
10K

93C46

VCC
NC
NC
GND

U1102

CO1100_4
100nF

7
8
14
13

8
7
6
5

CONFIG EEPROM

R1108
4K7

C1121
33pF

46
AVCC
AGND

USB
Device

16
VCC
GND
15

3
42
VCC
VCC

45

1
2

14
31
VCCIOA
VCCIOB

GND
GND
GND
GND
9
18
25
34

20
VCC
GND
10

rev. 1.0 - 12/2009


10

Service Manual
075.1

Main board - CPU USB I/O (2825900V)

10-29

LCD_CL1
LCD_CL2
LCD_DD0
LCD_DD1
LCD_DD2
LCD_DD3
LCD_FRM
LCD_ENABLE

A0
A1

nCS3

nWR

[3]
[2,3]

[3,10]

[2,3,11]

[2,3,10,11] BD[0..15]

[2] SPI_MPLEX_CS2

[2,4] SPI1_ADC_DAT

[2] SPI_MPLEX_CS1
[2,4] SPI1_CLK
[2,4] SPI1_DAC_DAT

[3]
[3]
[3]
[3]
[3]
[3]
[3]
[2]

CO1200
100nF

10

+3.3V

R1234
470R

GND

1
19

2
3
4
5
6
7
8
9

CO1201
100nF

U305C
74LVC32

14
13
12
11
10
9
8
7
17
16

WR

DB0
DB1
DB2
DB3
DB4
DB5
DB6
DB7
A0
A1

GND

GND

18
17
16
15
14
13
12
11

Vref

19

20

CO1204_1
100nF

U1202
MAX5100

OUT D

OUT C

OUT B

OUT A

+5V

L1209
L1208
L1226
L1210

J1200

GND

CO1203_2
100nF

+5V

GND

C1207
1nF

GND

+3.3V

CO1204_2
100nF

GND

C1208
33pF

AUDIO_TRACK
L1225
2K7

FV_ReadHead_DAC1 [10]

CO1202
100nF

GND

L1222
2K7
CONTRAST

2K7

L1260

C1260
33pF

VCC_OUT
1
3
5
7
9
11
13
15
17
19

MicroMatch20

2
4
6
8
10
12
14
16
18
20

CO1205_2
100nF

GND

1
3
5
7
9
11
13
15
17
19
21
23
25
R1217
R1219
R1218
C/D DISP.
READ DISP.

100R
100R
100R

100R
100R
100R

The information contained herein is the


property of Neopost Technologies BV,
Drachten, the Netherlands. Any copying
or reproduction of this document in any
form and/or disclosure to other parties
without the express written consent of
Neopost Technologies BV is strictly
prohibited.

GND

CONBOX26

VCC_OUT
J1201
2
4
6
8
10
CE DISP. 12
WRITE DISP.
14
RESET DISP.
16
18
20
22
24
26

R1213
R1216
R1215

SI62 LCD connection

COLOR LCD connection

FV_ReadHead_DAC0 [10]

R1244
100R

R1241
100R

C1200
100nF

100R

2K7
2K7
2K7
2K7

2K7
2K7
2K7
2K7

2K7
2K7
2K7
2K7

L1202
L1206
L1203
L1207

L1200
L1201
L1204
L1205

R1260

GND

CO1205_1
100nF

GND

R1239
39K

R1237
10K

U601C
74HCT14_5
6
5

100R
100R
100R
100R

100R
100R
100R
100R

100R
100R
100R
100R

R1209
R1205
R1212
R1222

R1200
R1201
R1202
R1208

R1223
R1224
R1250
R1225

D1200
BAT54S

U1201
74LVC245

B1
B2
B3
B4
B5
B6
B7
B8

18
17
16
15
14
13
12
11

U1200
74LVC245

B1
B2
B3
B4
B5
B6
B7
B8

+5V

GND

DIR
OE

A1
A2
A3
A4
A5
A6
A7
A8

+3.3V

GND

CO1203_1
100nF

+3.3V

8 6

BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7

FAST DAC

GND

GND

R1214
470R

R1233
10K

DIR
OE

1
19

A1
A2
A3
A4
A5
A6
A7
A8

+3.3V

2
3
4
5
6
7
8
9

+3.3V

20

VCC

GND

10

VCC

GND

20

LDAC

C1202

2K7

2K7

C1210
1nF

R1236

GND

+5V
R1270
1K
21
20
19
18
17
16
15
14

21
20
19
18
17
16
15
14

R1221
470R

U601F
74HCT14_5
12
5 13

GND

R1220
470R

21
20
19
18
17
16
15
14
B1
B2
B3
B4
B5
B6
B7
B8

A1
A2
A3
A4
A5
A6
A7
A8

B1
B2
B3
B4
B5
B6
B7
B8

A1
A2
A3
A4
A5
A6
A7
A8

+5V +3.3V

GND

B1
B2
B3
B4
B5
B6
B7
B8

GND

2
22

3
4
5
6
7
8
9
10

R1265
1K

A1
A2
A3
A4
A5
A6
A7
A8

+3.3V

nRD
4

nRD

Otto Tuil

Code:

USER INTERFACE

[3]

[2,3,10,11]

LCD_RESET [2]

SI62_LCD_OE [2]

nCS4

[2,3,10,11]

[3]

[2,3,10,11]

[2,3,10,11]

SI62_LCD_OE [2]

time: 11:49:22

2825900V

A3

Sheet 12 of 12
Size

01

Rev:

[2,3,10,11]
[2,3,11]

nRD
nWR
2
22

GND

[3]

SI62_LCD_CD [2]
nCS4

R1245
470R

U305D
74LVC32

13

12

BD[0..15]

nCS5

U305B
74LVC32

GND

BD[0..15]

3
4
5
6
7
8
9
10

U1205
74LVX3245

DIR
OE

BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7
11

U1204
74LVX3245

DIR
OE

+5V +3.3V

GND

2
22

BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7

U1203
6
74LVX3245

DIR
OE

3
4
5
6
7
8
9
10

Andromeda DS-70 mainboard

100R
100R

100R

100R

100R

100R
100R
100R
100R
100R
100R
100R
100R

GND

33pF

C1206

R1204
10K

+5V +3.3V

Modified: Wednesday, August 20, 2008

Drawn:

Title:

R1243
R1242

R1240

R1238

GND

TECHNOLOGIES BV
PO BOX 20 9200 AA DRACHTEN
DE TIJEN 3 DRACHTEN THE NETHERLANDS
TEL: +31 512 589 300 / FAX: +31 512 589 399

2K7
2K7

L1221

L1224
L1223

2K7

L1220

L1219

GND

33pF

C1205

R1230
R1227
R1226
R1232
R1231
R1229
R1228
R1235

33pF

C1204

GND

2K7
2K7
2K7
2K7
2K7
2K7
2K7
2K7

33pF

C1203

GND

L1215
L1211
L1216
L1212
L1217
L1213
L1218
L1214

GND

33pF

GND

33pF

C1201

R1211
10K

+5V

SI62 keyboard readout


+5V

R1207
10K

+5V

R1210
10K

+5V

R1206
10K

+5V

R1203
10K

+5V

24
VCCB

10

SHDN

15

VDD

GND

18

24
VCCB

1
VCCA

GND
GND
GND
13
12
11
24
VCCB

1
VCCA

GND
GND
GND

13
12
11
1
VCCA

GND
GND
GND

10-30
13
12
11

075.1
Service Manual

Main board - User interface (2825900V)

rev. 1.0 - 12/2009

Service Manual

075.1

GND

U100
DS2431P

NC
NC
NC
DATA

GND

GND

JST2

1
2

J100

3
4
5

ID-Tag (2994504Z)

rev. 1.0 - 12/2009

10-31

075.1

10.3

Service Manual

Product coding for CRM

10.3.1 Failure symptoms


Code

Failure symptoms

SD550

Unable to run mail

SD560

Document jam

SD570

Unable to connect to OLS

SD580

Document feeding issue

SD810

Envelope feeding issue

SD820

Envelope jam

SD830

Display operation issue

SD840

Noisy machine

SD850

No power

SD860

Envelope sealing issue

SD990

Symptom not coded

10.3.2 Module
Code

Module

D042

Document Feeder

D081

Collator

D167

Document Folder

D244

Envelope Feeder

D281

Empty Envelope Transport

D364

Document Insertion Area

D401

Envelope Ejection Area

D444

Envelope Sealing and Exit Area

D511

Main Drive

D551

Miscellaneous Area

D707

Vertical stacker

D820

Server

D831

Customer environment / operation

D840

OpCo / Service operation

D890

Origin not found

D990

Module not coded

10-32

rev. 1.0 - 12/2009

Service Manual

075.1

10.3.3 Failure origins


Code

Module

Failure origin

D032250

Document Feeder

Photocell

D042250

Document Feeder

Photocell

D042260

Document Feeder

DFC Thickness detector

D042270

Document Feeder

Wiring

D042450

Document Feeder

Paper pull roller

D042460

Document Feeder

Separation roller

D042470

Document Feeder

Transport rollers

D042490

Document Feeder

Axle

D042510

Document Feeder

Clutch

D042530

Document Feeder

Belt

D042540

Document Feeder

Belt tensioner

D042550

Document Feeder

Pressure spring

D042580

Document Feeder

OMR paper guides

D042590

Document Feeder

OMR reading head

D042600

Document Feeder

Lever high capacity feeder

D042990

Document Feeder

Origin not coded

D081250

Collator

Photocell

D081260

Collator

Motor

D081270

Collator

Switch

D081280

Collator

Wiring

D081450

Collator

Collator roller

D081460

Collator

Bearing

D081470

Collator

Axle

D081490

Collator

Pulley

D081500

Collator

Timing belt

D081510

Collator

Collator belt

D081550

Collator

Pulse disc

D081560

Collator

Stop positioner

D081990

Collator

Origin not coded

D167250

Document Folder

Photocell

D167260

Document Folder

Wiring

D167450

Document Folder

Fold roller

rev. 1.0 - 12/2009

10-33

075.1

Service Manual

Code

Module

Failure origin

D167460

Document Folder

Bearing

D167470

Document Folder

Axle

D167480

Document Folder

Gear

D167490

Document Folder

Clutch

D167500

Document Folder

Pulley

D167510

Document Folder

Belt

D167540

Document Folder

Folding knife

D167570

Document Folder

Cam disc

D167620

Document Folder

Brake disc

D167990

Document Folder

Origin not coded

D244250

Envelope Feeder

Wiring

D244450

Envelope Feeder

Feed roller

D244460

Envelope Feeder

Jogger roller

D244470

Envelope Feeder

Separation roller

D244480

Envelope Feeder

Bearing

D244490

Envelope Feeder

Axle

D244500

Envelope Feeder

Gear

D244510

Envelope Feeder

Clutch

D244520

Envelope Feeder

Pulley

D244530

Envelope Feeder

Belt

D244550

Envelope Feeder

Hopper side guide

D244560

Envelope Feeder

Semi automatic envelope separation

D244990

Envelope Feeder

Origin not coded

D281250

Empty Envelope Transport

Photocell

D281260

Empty Envelope Transport

Wiring

D281450

Empty Envelope Transport

Transport roller

D281460

Empty Envelope Transport

Track roller

D281470

Empty Envelope Transport

Flap roller

D281480

Empty Envelope Transport

Bearing

D281490

Empty Envelope Transport

Axle

D281500

Empty Envelope Transport

Gear

D281510

Empty Envelope Transport

Clutch

D281520

Empty Envelope Transport

Pulley

10-34

rev. 1.0 - 12/2009

Service Manual

Code

Module

Failure origin

D281530

Empty Envelope Transport

Belt

D281550

Empty Envelope Transport

Flap scraper

D281560

Empty Envelope Transport

Friction brake

D281990

Empty Envelope Transport

Origin not coded

D364250

Document Insertion Area

Photocell

D364260

Document Insertion Area

Finger solenoid

D364270

Document Insertion Area

Wiring

D364450

Document Insertion Area

Insert roller

D364460

Document Insertion Area

Bearing

D364470

Document Insertion Area

Axle

D364480

Document Insertion Area

Gear

D364490

Document Insertion Area

Clutch

D364500

Document Insertion Area

Pulley

D364510

Document Insertion Area

Belt

D364520

Document Insertion Area

Leaf spring

D364540

Document Insertion Area

Fingers

D364990

Document Insertion Area

Origin not coded

D401250

Envelope Ejection Area

Ejection solenoid

D401260

Envelope Ejection Area

Photocell

D401270

Envelope Ejection Area

Wiring

D401450

Envelope Ejection Area

Ejection roller

D401460

Envelope Ejection Area

Bearing

D401470

Envelope Ejection Area

Axle

D401480

Envelope Ejection Area

Gear

D401490

Envelope Ejection Area

Pulley

D401500

Envelope Ejection Area

Belt

D401520

Envelope Ejection Area

Spring

D401990

Envelope Ejection Area

Origin not coded

D444250

Envelope Sealing and Exit Area

Solenoid

D444260

Envelope Sealing and Exit Area

Photocell

D444270

Envelope Sealing and Exit Area

Water level detection

D444280

Envelope Sealing and Exit Area

Wiring

D444450

Envelope Sealing and Exit Area

075.1

Envelope reverse roller

rev. 1.0 - 12/2009

10-35

075.1

Service Manual

Code

Module

Failure origin

D444460

Envelope Sealing and Exit Area

Envelope sealing roller

D444470

Envelope Sealing and Exit Area

Bearing

D444480

Envelope Sealing and Exit Area

Axle

D444490

Envelope Sealing and Exit Area

Gear

D444500

Envelope Sealing and Exit Area

Pulley

D444510

Envelope Sealing and Exit Area

Belt

D444540

Envelope Sealing and Exit Area

Moistening cloth

D444560

Envelope Sealing and Exit Area

Brush holder

D444990

Envelope Sealing and Exit Area

Origin not coded

D511250

Main Drive

Main motor

D511260

Main Drive

Photocell

D511270

Main Drive

Wiring

D511450

Main Drive

Bearing

D511460

Main Drive

Axle

D511470

Main Drive

Gear

D511480

Main Drive

Clutch

D511490

Main Drive

Pulley

D511500

Main Drive

Belt

D511520

Main Drive

Pulse disc

D511990

Main Drive

Origin not coded

D551020

Miscellaneous Area

Main Board

D551030

Miscellaneous Area

Communication board

D551040

Miscellaneous Area

Connection board

D551050

Miscellaneous Area

Display Board

D551060

Miscellaneous Area

ID tag

D551125

Miscellaneous Area

Software

D551250

Miscellaneous Area

Power supply

D551260

Miscellaneous Area

Dongle

D551270

Miscellaneous Area

Fuse

D551280

Miscellaneous Area

Power switch

D551290

Miscellaneous Area

Cover switch

D551300

Miscellaneous Area

Power cable

D551450

Miscellaneous Area

Cover

10-36

rev. 1.0 - 12/2009

Service Manual

075.1

Code

Module

Failure origin

D551750

Miscellaneous Area

Display assembly

D551990

Miscellaneous Area

Origin not coded

D707250

Vertical stacker

Main board

D707260

Vertical stacker

Clutch

D707270

Vertical stacker

Wiring

D707280

Vertical stacker

Photocell

D707290

Vertical stacker

Switch

D707450

Vertical stacker

Cover

D707460

Vertical stacker

Transport roller

D707470

Vertical stacker

Axle

D707480

Vertical stacker

Gear

D707490

Vertical stacker

Side guide

D707750

Vertical stacker

Gear box

D707760

Vertical stacker

Stack mechanism

D707770

Vertical stacker

Top load assembly

D707990

Vertical stacker

Origin not coded

D820125

Server

OLS server not available

D820990

Server

Origin not coded

D831250

Customer environment / operation

Phone adaptor

D831260

Customer environment / operation

Phone line filter

D831270

Customer environment / operation

Phone cable

D831920

Customer environment / operation

User setting

D831925

Customer environment / operation

Supervisor setting

D831930

Customer environment / operation

PABX setting

D831935

Customer environment / operation

No phone line

D831940

Customer environment / operation

Phone line too far

D831945

Customer environment / operation

Several devices on phone socket

D831950

Customer environment / operation

Envelope not appropriate

D831955

Customer environment / operation

Document not appropriate

D831960

Customer environment / operation

Incorrect user operation

D831990

Customer environment / operation

Origin not coded

D840915

OpCo / Service operation

ERP(SAP) incorrect operation

D840920

OpCo / Service operation

Service settings

rev. 1.0 - 12/2009

10-37

075.1

Service Manual

Code

Module

Failure origin

D840930

OpCo / Service operation

Incorrect Service operation

D840990

OpCo / Service operation

Origin not coded

D890990

Origin Not Found

Origin not found

D990990

Module Not Coded

Origin not coded

10-38

rev. 1.0 - 12/2009

Service Manual

10.4

075.1

Checklist training operator

Check

Subject
Introduction
-

Explain machine function

Operator manual: read it!

Safety
-

Keep long hair, jewellery, fingers away from rotating parts

Power: earthing, local mains voltage

Explain process flow


Starting up
-

Install document feeder trays

Install slide and envelop catch tray

Connect to mains, power on

Loading documents: document orientation, side guides,


separation

Loading envelopes: side guides, stacker side guides,


separation

Sealing: fill water reservoir

Automatic
-

Explain Automatic

Select a job
-

Job info, explain all icons

Test run

Counters

Explain buttons on control panel


Daily mail
Create a new job

Job wizard

Job settings
-

Document settings

Fold settings

rev. 1.0 - 12/2009

Envelope settings

Double Feed Control settings

10-39

075.1

Check

Service Manual

Subject
-

Job name

Display settings

Supervisor Menu
-

System info

Options information and system information

Test menu

Job menu

Edit a job
Copy a job
-

Save an Automatic job

Delete a job
Fault finding
-

Error messages

Special errors (technical errors)

Warning screen (cover open)

Last error screen, supervisor menu

Clearing stoppages
-

Show all areas

How to remove jams

Operator troubleshooting
-

Adjust insert position, explain when and how

Adjust insert fingers, explain when and how

Adjust address position

Maintenance, daily
-

Clean exterior

Clean sealing table and rollers

Maintenance, weekly
-

Replace brushes

Replace moistening cloth

Maintenance when necessary: clean sensors


Options

10-40

rev. 1.0 - 12/2009

Service Manual

Check

075.1

Subject
-

Activate an option

Reading
-

Explain functioning of reading (codes and marks)

Document orientation

Reading settings in Job menu

Reading Test menus

Adjust reading head position

Reading errors

Mailing / Franking options


-

Mailing / Franking settings in Job menu

Online services
-

Connection status

Manual connection

New messages (install new config / job)

Messages

Configuration (modem volume)

MPPC
-

MPPC settings in Job menu

MaxiFeeder
-

Adjust side guides

Document separation

Feeding documents

High Capacity Feeder


-

Installation of feeder tray

Adjust side guides

Document separation

Feeding documents

High Capacity Vertical Stacker


-

Installation

Adjust side guides

Side exit

rev. 1.0 - 12/2009

10-41

075.1

Check

Service Manual

Subject
Envelope / paper characteristics:
-

Window quality

Glue

Internal/external glueing

10-42

Storage (humidity and temperature)

Fingers

rev. 1.0 - 12/2009

Service Manual

10.5

075.1

High Capacity Vertical Stacker

10.5.1 Process description

CL1

The processing of envelopes or document sets is as follows:


1
2
3
4

The exit photocell of the inserter system (PH4) sees the envelope or document set. This
activates clutch CL1 of the vertical stacker.
The rollers 1 to 6 transport the envelope into the stacker.
The envelope lands on a shovel and the stacker photocell PH1 detects the end of the
envelope.
The shovel lifts the envelope, the fingers pick up the envelope and stack it. A slotted
photocell monitors this stacker cycle.

rev. 1.0 - 12/2009

10-43

075.1

Service Manual

10.5.2 (Dis)assembly - High Capacity Vertical Stacker

Note: Handle the high capacity vertical stacker with care. Never disassemble the stack
mechanism.
Remove covers
1

Top cover assy (4)


To remove the top cover assy:
1
2
3

Remove the guard plate (5).


Remove the six torx screws that hold the cover plate.
Remove the top cover assy.

Bottom plate (2)


1
2
3

Place the machine carefully at the back side on a felt path.


Remove the six screws that hold the bottom plate.
Remove the bottom plate.

Side cover LH (1)


1
2
3

Remove the screw from the bottom plate (2) that holds the side cover.
Remove the screw from the top cover assy (4) that holds the side cover.
Remove the third screw that holds the side cover.

10-44

rev. 1.0 - 12/2009

Service Manual

075.1

Turn the cover and remove it.

Side cover RH (3)


1
2
3
4

Remove the screw from the bottom plate (2) that holds the side cover.
Remove the screw from the top cover assy (4) that holds the side cover.
Remove the third screw that holds the side cover.
Turn the cover and remove it.

Stack mechanism
1

In case the stack mechanism is defective, the complete unit has to be replaced.
To replace the stack mechanism:
1
2
3
4
5
6
7
8

Remove the top cover assy ( Remove covers on page 10-44).


Remove the bottom plate.
Remove the side covers.
Disconnect the wire at the pulse disc sensor in the stack mechanism (5).
Remove the gear 29T from the RH side (7).
Remove the screw that holds the support plate RH (6) and remove the plate.
Remove the screw that holds the support plate LH (2) and remove the plate.
Slide complete stacker mechanism (4) from the back plate.

Note: On replacement make sure that both stack units are synchronized. See
Synchronizing stacker mechanism on page 10-54.

rev. 1.0 - 12/2009

10-45

075.1

Service Manual

Back guide

Remove the back guide assy


1
2
3
4

Remove the guard plate.


Disconnect the connector (2) of the back guide.
Press the leaf springs (1) that hold the guide axles to the inside direction.
Pull the back guide (3) out of the stacker.

When you reinstall the back guide: push the pins through the holes on both sides until you hear
a click on both sides. If you do not hear a click, the thick part of the guide axle did not pass the
leaf spring completely. In that case use a screw driver to enforce the leaf spring.

10-46

rev. 1.0 - 12/2009

Service Manual

075.1

Remove the pressure arm

1
2
3
4
5
6
7
8

Remove the two torx screws that hold the back guide cover (1).
Slide the back guide cover down and lift it from the back guide assy.
Remove the cable guide plate (2) at the bottom.
Remove the nuts that secure the guide rail (3).
Slide the guide rail from the pressure arm (4).
At the front side unscrew the weights (5).
Remove both rollers, plastic rings and screw.
Remove the pressure arm (4).

Note: On replacement take care of the wiring.

rev. 1.0 - 12/2009

10-47

075.1

Service Manual

PCB

1
2
3
4

Remove the RH cover ( Remove covers on page 10-44).


Disconnect all connectors from the PCB.
Remove the nut and both washers (2) that hold the PCB (1).
Remove the PCB carefully.

Leaf spring assy

1
2
3

Remove the guard plate.


Remove the two screws (1) that hold the leaf spring assy (2).
Remove the leaf spring assy.

10-48

rev. 1.0 - 12/2009

Service Manual

075.1

Gear box assy

1
2
3
4

Remove the two torx screws (1) and screw (2) that hold the envelope transportation
table (3).
Remove the envelope transportation table.
Open the pinch (4).
Lift the safety plate and remove the gear box assy (5) from the axle.

rev. 1.0 - 12/2009

10-49

075.1

Service Manual

Transportation rollers
1

Remove the both side covers, the top cover assy and the envelope transportation table.

Rollers on axle (1)


1
2
3
4

Remove spring clip, washer and bearing from the RH side of axle (1).
Slide the axle to the left.
Remove gear 18T from the axle. Take care of the cyl. pin.
Remove the rollers (2) from the axle. Take care of the cyl. pins.

Axle assy (3)


1
2
3
4
5

Remove the clutch (7), spacer, washer and bearing from the RH side of axle (3) (see
Clutch on page 10-50).
Remove the spring clip, washer and bearing from the LH side of axle (3).
Slide the axle to the left.
Remove gear 18T from the axle. Take care of the cyl. pin.
Slide the axle to the right and remove it.

Clutch
1
2
3
4
5

Remove the RH side cover and top cover assy.


Remove the support RH (6).
Remove the two screws that hold the connection pivot (8) and remove the pivot.
Remove the spring clip, washer, gear 20T (4), slip clutch (5) and coupling plate from the
axle.
Disconnect the clutch (7) and remove it from the axle.

10-50

rev. 1.0 - 12/2009

Service Manual

075.1

(Dis)assembly sensors
Microswitch in back guide

1
2
3
4

Remove the back guide from the stacker.


Remove the two torx screws that hold the back guide cover (see Remove the pressure
arm on page 10-47).
Slide the back guide cover down and lift it from the back guide assy.
Remove the nut that holds the microswitch.

Safety switch

1
2

Remove the top cover assy and the RH side cover.


Remove the safety switch.

rev. 1.0 - 12/2009

10-51

075.1

Service Manual

Photocell transmitter (LED)

1
2

Lift the safety plate (2) to get access to the screw (1) that holds the transmitter (3).
Remove the transmitter.

10-52

rev. 1.0 - 12/2009

Service Manual

075.1

Photocell receiver (sensor)

1
2
3
4
5

Remove the back guide.


Remove the envelope transportation table (1).
Remove the photocell transmitter to get access to the photocell receiver (2).
Put a screw driver through the hole of the transmitter and remove the screw that holds the
receiver.
Remove the receiver.

rev. 1.0 - 12/2009

10-53

075.1

Service Manual

10.5.3 Preventive maintenance


Average preventive service visits should take place at approximately 160.000 inserts (see
service menu, service counters). The table below shows the intervals.
Please note that there is a statistical relationship between the actual average monthly volume
and the service requirements of the machine. Significant larger average volumes might double
the yearly service requirements.
Maintenance

Number of cycles

Service visit

+/- 160.000

160k

+/- 330.000

160k

+/- 500.000

500k

+/- 660.000

160k

+/- 830.000

160k

+/- 1.000.000

500k

10

+/- 1.660.000

160k

11

+/- 1.800.000

160k

....

....
Note
It is recommended to service the machine at least twice a year.
160K service visit

Clean photocells.

Clean the transportation area / transportation rollers.

Check the adjustment of the side guides.


500K service visit

Perform 160K activities

Replace transportation rollers (see Drive on page 10-60, item 29) and drive axle assy
(item 1) if necessary.

Replace the gear box assy (see Drive on page 10-60, item 2) and the leaf spring assy
(item 6) if necessary.
10.5.4 Troubleshooting
Synchronizing stacker mechanism
If both stacker units are not running synchronic, synchronize them as follows:
1
2
3

Remove the RH side cover.


Make sure that the leaf spring rests in the notch of the curved gear. If not, turn the upper
axle in the stacker unit until you hear a click.
Repeat this for the left hand side.

10-54

rev. 1.0 - 12/2009

+5V

VCC

LM393

LM393

VEE

11

GND

CO102
100nF

H100
4.3mm

74HCT14

IC100E
10

GND

+5V

GND

CO100
100nF

22R
R122

R121
22R

D100
BAT54S

+5V

GND

R109 +5V
10k

74HCT14

14

IC102C
VCC 8

74HCT14

GND

IC100F
12

IC102B

13

R108
10k

JST7

1
2
3
4
5
6
7

J100

IC100G

+5V
SDA
SCL
StackerPresent
GND
+24V
StackerClutch

+5V

Accessory connector

+5V

H101
4.3mm

GND

H102
4.3mm

74HCT14

IC100D
8

GND

GND

GND

D101
BAT54S

1
2
3

13

15
14

A0
A1
A2

INT

SDA
SCL

IC101

+5V

16
VCC
GND

rev. 1.0 - 12/2009


PCF8574T

P0
P1
P2
P3
P4
P5
P6
P7

4
5
6
7
9
10
11
12

CO101
100nF
GND

GND

+5V

+5V

R105
1k

C101
100nF

GND

C100
100nF

R115
10k

GND
+5V

IC100C
6
5

LM393

GND

C103
100nF

GND

R116
10k

R123
1k

R124
10k

C102
100nF

R107
10k

R104
10k

R102
10k

GND

+5V

GND

IC102A

220k

R114
10k R113
10k

R118

74HCT14

R117
4.7k

74HCT14

IC100A
2
1

74HCT14

IC100B
3
4

R103
1k

+5V

D103
40V 1A

D102
12V

COVER

GND

GND

R112
15k

1
2
3
4
5
6
7
8
9

1 +24V
2 NC
3 Interlock Cover

+5V
One turn photoswitch
GND
Stacker Full microswitch
GND
+5V
Start Stacker Rx
+5V
Start Stacker Tx

JST2

1
2

J102

1 +24V
2 StackerClutch

Clutch

JST3

1
2
3

J103

Cover

R111
220R

JST9

1
2
3
4
5
6
7
8
9

J101

Inputs

GND

GND

+5V

Service Manual
075.1

10.5.5 Electrical diagram HCVS-1 (2825913J)

10-55

075.1

Service Manual

10.5.6 Parts list


Covers

10-56

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
*
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Bottom plate
Side guide RH
Side guide LH
Side guide kit (both LH and RH)
Magnetic clip
Wedge
Guard plate (top)
Guard plate (top)
Nut M4 (self-locking)
Screw 5.0x14
Torx screw m4x8
Round head screw m3x6
MPPC camera V2
Cover RH
Top cover assy.
Stacker cover RH
Cover LH
Stacker cover LH
Decorative cover
Finger knob assy.
Mounting bracket

2825692D
2825696H
2825697J
2825828V
2957090B
2825725N
2825613W
2825809A
2053621N
2989183G
2053850B
2454302P
2818114K
2825709W
2825796M
2825883C
2825712Z
2825705S
2825714B
2825667C
2825711Y

1
1
1
2
2
1
1
7
10
8
2
1
1
1
1
1
1
1
1
1

Remarks
*
*

See note

See note
See note
Optional

See note
See note

Note
In case the optional MPPC is mounted.

rev. 1.0 - 12/2009

10-57

075.1

Service Manual

Frame parts etc.

10-58

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
12
13
13
14
15
16
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

Connection cable (external)


Tension spring
Not used
Mounting clamp
Torx screw M4x8
Sensor (including holder)
Back plate
Spacer 8x4,3x10mm
Strain relief
Bottom frame assy.
Support RH
Support LH
Connection frame LH
Cross bar
Round head screw m4x10
Connection pivot (left)
Spring clip 6-8mm
Connection pivot (right)
Envelope transportation table
Bracket
Connector 3p (JST)
Safety plate (assy)
Grommet
Retaining leaf spring
Torx screw m4x8
Microswitch (including lever)
PCB
Nut m4
Wire saddle
Print-board holder
Pan head tapping screw
Nut m3 (self-locking)
Washer 9 x 4,3 x 0,8mm
Paint piercing washer 8x4,3x0,5
Led (including holder)
Connection frame RH

2825932D
2825890K

1
2

2121489J
2825892M
2042453E
2825611U
2046919G
2825602K
2825813E
2825748M
2825745J
2825621E
2825765E
2454314B
2825614X
2052446P
2825617A
2825612V
2825622F
2969833A
2825721J
2120851U
2825616Z
2053850B
2989056Z
2825913J
2451902P
2814768Z
2041075U
2453853W
2053628V
2453702P
2052431Y
2042452D
2825628M

1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
4
2
16
1
1
1
2
2
2
1
1
1
1
1

rev. 1.0 - 12/2009

Remarks

10-59

075.1

Service Manual

Drive

10-60

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Drive axle assy.


Gear box assy.
Screw 5.0x14
Clutch ccw 8mm
Spacer 12x8,3x3mm
Leaf spring assy.
Torx screw M4x8
Gear 21T
Gear 29T
Cyl. pin 2,5x24mm
Coupling plate
Drive axle
Gear 18t
Slip clutch
Spring clip 9-12mm
Washer 14x8,2x0,8mm
Cyl. pin 2,5x16
Bearing 10mm
Washer 16x10,2x0,8mm
Gear 20t
Bearing 6mm
Transportation roller
Spring clip 6-8mm
Transportation axle
Spring clip 7-9mm
Gear 32T assy.
Gear 30T assy.
Pressure spring
Transportation roller
Washer 12x6,2x0,8mm

2825849S
2825826T
2989183G
2930536R
2041050T
2825827U
2825892M
2825751Q
2825752R
2052349N
2958056H
2825647G
2957376Z
2947396D
2052455Y
2040141W
2052346K
2042426B
2040143Y
2964199G
2042424Z
2042851U
2052446P
2825641A
2052442K
2825653N
2825655Q
2033520Z
2042976Z
2040140V

rev. 1.0 - 12/2009

Remarks

1
1
1
1
1
1
2
1
1
1
1
1
2
1
4
1
4
4
4
1
4
4
5
2
3
1
1
4
2
4

10-61

075.1

Service Manual

Backguide

10-62

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

Retaining plate
Sealing plug
Roller 30mm
Cable guide
Microswitch
Guide rail
Pressure arm
Guide axle
Weight (for stacker)
Set screw m5x25
Washer 16x10,2x0,8mm
Torx screw m4x8
Grommet
Nut M4 (self-locking)
Nut m3 (self-locking)
Mounting plate
Backguide cover
Backguide frame

2825837E
2040905S
2969579L
2825810B
2825265J
2825772M
2825785A
2825632R
2969580M
2082849J
2040143Y
2053850B
2120851U
2053621N
2053628V
2825811C
2825719G
2825759Y

rev. 1.0 - 12/2009

Remarks

1
2
2
1
1
1
1
2
2
1
2
3
2
6
1
1
1
1

10-63

075.1

Service Manual

Stack mechanism

10-64

rev. 1.0 - 12/2009

Service Manual

075.1

Number

Description

Part number Quantity

1
2
3

Pulse disc sensor (assy.)


Stack mechanism unit complete
Screw 5.0x14

2975505J
2825432Z
2989183G

Remarks

1
1
4

10.5.7 Recommended spare parts HCVS-1

Page ref.

Legend
no.

Description

Part No

Stock per
number of
installed
machines
1

10

Remarks

50

page 10-56

2&3

Side guides

2825696H
& 2825697J

page 10-58

26

Micro switch

2989056Z

35

Led

2042452D

Drive axle assy.

2825849S

Gear box assy

2825826T

Clutch

2930536R

Leaf spring assy

2825827U

26

Gear 32T assy

2825653N

27

Gear 30T assy

2825655Q

29

Transportation roller

2042976Z

page 10-62

Micro switch

2825265J

page 10-64

Pulse disc sensor

2975505J

Stack mechanism unit

2825432Z

page 10-60

rev. 1.0 - 12/2009

combined order
number:
2825828V

10-65

075.1

Service Manual

10.5.8 Specifications High Capacity Vertical Stacker


Model

HCVS-1

Type

high capacity vertical stacker


Suitable for all kinds of mail sets that consist of at least one 80 grams
envelope and one folded document (80 gram).

Power consumption

Low voltage supplied by the inserter system.

Approvals

EMC Certificate conform EMC-Directive.


FCC Certificate conform 47CFR, part 15.
UL Listed I.T.E. (Information Technology Equipment),
conform UL-IEC 60950-1, file: E153801.
Conform NEN-EN-IEC 60950-1 and derivatives.

Height
Width
length

550 mm(21.7 inch)


440 mm (17.3 inch)
360 mm (14.2 inch)

Weight

12 kg (26.5 lbs)

Noise level

See 8.1 Machine specifications on page 8-1

Operating temperature

10C - 40C (50F-104F)

Humidity

30%-80%

Stacker capacity

325 envelopes, depending on application

10-66

rev. 1.0 - 12/2009

2825918P
WIRING

2
1

TX LOC

Connector B for backward


compatibility

ID TAG
2994504Z

CLOSER SOLENOID

EJECT SOLENOID

2
1

1
2

2
1

4
3
2
1

6
5
4
3
2
1

10
9
8
7
6
5
4
3
2
1

SEE SHEET 2

RX COLLATOR

2
1

8
7
6
5
4
3
2
1

CLUTCH CLUTCH FINGERS


Folder
SOLENOID
Folder
Reverse Forward

TX CLOSER

Inter
Connect

J650

J1200

B*

J700

J1201

J502

5
4
3
2
1

J603

J602

J601

J600

MAIN
PULSEDISC
2042819L

5
4
3
2
1
12
11
10
9
8
7
6
5
4
3
2
1

J501

J101

J100

J904

J604

J500

TX EXIT

RX EXIT

2
1

TX FLAP

READING
HEAD
ASSY
2989434T

TX ENV.TRACK

2
1

RX ENV.TRACK

1
2

2
1

FRONT COVER

TOP COVER

2989056Z

2989056Z

J1000

J904

5
4
3
2
1

4
3
2
1

11
10
9
8
7
6
5
4
3
2
1

RX LOC

RX FLAP

1
2

1
2

USB DEVICE

+24V
COMMUNICATION
HORUS BOARD

SLOTTED
SWITCH
FT1
2975505J

RX READING
HEAD

SLOTTED
SWITCH
FT2
2975505J

J1120 J1102

CLUTCH FT1
CLUTCH FT2

J1100

J802

1
2

MOTOR
PAPERSTOP

SLOTTED
SWITCH
PAPERSTOP2
2975505J

SLOTTED
SWITCH
PAPERSTOP1
2975505J

SEE SHEET 3

1
2
3
4
5
6
7
8

SEALING SOLENOID

CLUTCH
Env.track

1
2
3
4
5

3 7 4

1
2
3

2
1
3
2
1

Inter
Connect

J102

J801

J800

J701

INPUT: 100 - 120 VAC 3.15A


200 - 240 VAC 1.5A
50/60 Hz
OUTPUT: + 24 V
4.5A

POWER SUPPLY

Sealing liquid sensor


assy. 2825246P

J903

J902

J901

1,2,3X

On J902

On J901

1
2
3
4
5
6

1
2
3
4
5
6
7
8

ADJ

+V

+V

+V

COM

COM

(AC)

1
2
3
4
5
6
7
8

1
2
3
4
5
6
7
8
9
10

2825917N
WIRING

BIG FEEDER (HCF)

OPTIONAL

3 4

5 6

3 4

5 6

3 7 4
5

Motorboard

MAXI FEEDER

OPTIONAL

TMU 1

2790171C

DFC FEEDER1
TOP

8 9 10

72

74

START

RUN

1
2

J1

S, T

A, L, Y

B*

S, T, U

1
2
3
4
5
6
7
8

2
4

MAINS LEAD

PLUG TYPE:
COUNTRY SPECIFIED
EURO 2989051U
USA
2989052V
2989053W
UK

FUSE:
230V: 2.5 A (2975543Y)
110V: 5 A (2121549W)

POWER INLET 2989005W

CON8

J530

Z (all power wiring)

MOTOR
COLLATOR

TX COLLATOR

2825917N

2825916M

2825915L

2825914K

2989036D

2989034B

2989032Z

2989028V

2989024R

2989022P

2989020M

2989018K

2989010B

2994536H

2994530B

2975500D - 230V
2975540V - 115V

5251

54

2994522T
2994526X

CONNECTED TO
CONNECTOR:
K

SLOTTED
SWITCH
COLLATOR
2975505J

WIRING PARTNUMBER:
2994520R

55

INCLUDES: MAINS FUSE

J3

124

230V: 5F (2989006X)
115V: 20F (2121281S)

FEED

FEEDER1/2/3 *

115V: 2989407Q
230V: 2989406P

TX READ HEAD

1
2

RX FOLDER

2
1

TX FOLDER

1
2

RX COLLATOR

2
1

TMU 1

2790171C

DFC FEEDER1
TOP

8 9 10

FEED

3
2
1

1
2
3
4
5
6
7
8
9
10
11
12

1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10

rev. 1.0 - 12/2009


1
2
3
4
5
6
7
8
9
10

10.6

73

OPTIONAL
ACCESSORY
STACKER

Service Manual
075.1

Total view electronics sheet 1/3

10-67

10-68

Backlight

1
2
3
4

J101

J210

J100

J103

WIRING DISPLAY 2989082B

COLOUR DISPLAY
AND TOUCH SCREEN
2994510F

J104

DISPLAY BOARD
2994502X

Touch screen

WIRING 2994544R
1
2
3
4

J1200

J100

KEYBOARD
2994508D

MAIN BOARD
2825900V

10.7

4
3
2
1

075.1
Service Manual

Total view electronics sheet 2/3

rev. 1.0 - 12/2009

E
J502

COMMUNICATION
+24V
HORUS BOARD

R
J1102

J1120

1
2
3

J1100

1
2
3
4
5

USB DEVICE

1
2
3
4
5

1
2
3
4
5
6
7
8

COMMUNICATION BOARD
2992000R

J402

C
J401

B
J101

1
2
3

1
2
3
4
5
6
7
8
9
10
11
12

MAIN BOARD
2825900V

RS 232

USB BOARD
2992003U

TEL

CONNECTION BOARD
2992001S

USB

J101

USB

J105

1
2
3
4
5

1
2
3
4
5

1
2
3
4
5
6
7
8
9
10
11
12

A, C, F, G

2994532D

P, E, Q, B
D, R

2994534F
2994548V

(CONNECTIVITY DISABLED)

P, H

(CONNECTIVITY ENABLED)

CONNECTED TO
CONNECTOR:

CONNECTIVITY DISABLED
WIRING PARTNUMBER:

CONNECTIVITY ENABLED

1
2
3
4
5
6

rev. 1.0 - 12/2009


1
2
3
4
5
6
7
8
9
10
11
12

10.8

J403

J108

Service Manual
075.1

Total view electronics sheet 3/3

10-69

075.1

10-70

Service Manual

rev. 1.0 - 12/2009