FPi-4030 Service Manual (Rev.1.2)

FPi 4030 Inserting System Service Manual Illustrated Parts List Operator Manual
Release: 07/2006
Revision: Item number:
0 51.0067.1001.00
SERVICE MANUAL FPi 4030 INSERTING SYSTEM
Note If you as a user of these documents should detect any difference to actual practical operation, or simple printing errors, please assist us in publishing error-free documents for the future by forwarding these errors with a copy of the faulty page to the address listed below. Any information and data contained in these documents will thus always be up to date. Thank you.
Your technical trainers
These service instructions contain copyright information. No part of these instructions may be copied or otherwise reproduced without prior written consent by Francotyp-Postalia. 2006 Francotyp-Postalia
Francotyp-Postalia GmbH Triftweg 21-26 16547 Birkenwerder, Germany FP release 07/2006: Ingenieurbro Dr. Helbig, Berlin
Page i2
Overview of the Service Documentation
1 2 3 4 5 6 7 8 9 10 11
THIS MANUAL HEALTH, SAFETY AND ENVIRONMENT GENERAL DESCRIPTION USER INTERFACE THE FPI 4030 INSERTING SYSTEM FAULT FINDING UPGRADING AND INSTALLING ACCESSORIES TECHNICAL SPECIFICATIONS ILLUSTRATED PARTS LIST APPENDIX FPI 4030 OPERATOR MANUAL
Please Note: Current versions of the illustrated spare parts list,recommended spare parts stock, wear parts and error messages can be looked up online in the Service Knowledge Database (SKD).
Release: 07/2006
0 51.0067.1001.00 Page i3
Page i4
SERVICE MANUAL FPi 4030 INSERTING SYSTEM Contents
Contents 1 This Manual.................................................................................................... 1-1

1.1 1.2 1.3 Abbreviations ..................................................................................................... 1-1 Terminology ....................................................................................................... 1-1 Release note ...................................................................................................... 1-1
Health, Safety and Environment .................................................................. 2-1

2.1 Safety instructions.............................................................................................. 2.1.1 General ................................................................................................ 2.1.2 Electrical safety .................................................................................... Symbols on the machine and in the manual ...................................................... End of life ........................................................................................................... 2-1 2-1 2-1 2-1 2-2
2.2 2.3
General description....................................................................................... 3-1

3.1 3.2 3.3 3.4 The system......................................................................................................... 3-1 Denominations ................................................................................................... 3-1 Paper flow .......................................................................................................... 3-2 Process Description ........................................................................................... 3-2 3.4.1 Document feeders................................................................................ 3-5 3.4.2 Document transport.............................................................................. 3-5 3.4.3 Collator................................................................................................. 3-6 3.4.4 Document folder................................................................................... 3-7 3.4.5 Envelope feeder ................................................................................... 3-9 3.4.6 Insert and exit track.............................................................................. 3-9 Electronics........................................................................................................ 3-11 3.5.1 PCB functions .................................................................................... 3-11 3.5.2 Schematic overview ........................................................................... 3-12 3.5.3 Connection with PC (Concorde application) ...................................... 3-13 3.5.4 The ID-tag (99.45.04)......................................................................... 3-14 3.5.5 Software package compatibility check ............................................... 3-16 Optional features.............................................................................................. 3-17 3.6.1 Optical Mark Recognition (OMR) ....................................................... 3-17 3.6.2 Flex Optical Mark Recognition (Flex OMR)........................................ 3-17 3.6.3 High capacity BRE MaxiFeederTM .................................................... 3-17 3.6.4 Insertn FrankTM (not available yet)................................................... 3-17 3.6.5 Online services................................................................................... 3-18 3.6.6 Intermediate transport ........................................................................ 3-18
3.5
3.6
User interface................................................................................................. 4-1

4.1 Operator menus ................................................................................................. 4-1
Release: 07/2006
0 51.0067.1001.00 Page i5
4.2 4.3
Job and Supervisor menus................................................................................ 4-1 Service menu .................................................................................................... 4-1 4.3.1 System settings ................................................................................... 4-2 4.3.1.1 Configuration ...................................................................... 4-2 4.3.1.2 Localisation......................................................................... 4-2 4.3.1.3 Software versions ............................................................... 4-3 4.3.1.4 Reset data .......................................................................... 4-3 4.3.1.5 Power up............................................................................. 4-3 4.3.1.6 Folder offset........................................................................ 4-3 4.3.1.7 Flap closer offset ................................................................ 4-3 4.3.2 Job settings ......................................................................................... 4-4 4.3.2.1 System output (FPi 4030 only) ........................................... 4-4 4.3.2.2 Document offset.................................................................. 4-5 4.3.2.3 BRE offset........................................................................... 4-5 4.3.2.4 Secure jobs......................................................................... 4-6 4.3.2.5 Flap closer .......................................................................... 4-6 4.3.3 Service Tests....................................................................................... 4-6 4.3.3.1 Photocells ........................................................................... 4-6 4.3.3.2 Digital inputs ....................................................................... 4-7 4.3.3.3 Actuators tests .................................................................... 4-8 4.3.3.4 Run in ................................................................................. 4-8 4.3.3.5 DFC test.............................................................................. 4-9 4.3.4 Service counters................................................................................ 4-10 4.3.5 OMR .................................................................................................. 4-10 4.3.5.1 OMR code definition ......................................................... 4-10 4.3.5.2 Read-code test ................................................................. 4-11 4.3.6 Diagnostics ........................................................................................ 4-13 4.3.6.1 Start test ........................................................................... 4-13 4.3.6.2 Error counters ................................................................... 4-13 4.3.6.3 Last error list ..................................................................... 4-13 4.3.7 Online service.................................................................................... 4-14 4.3.7.1 Server port ........................................................................ 4-14 4.3.7.2 Reset CB data .................................................................. 4-14 4.3.7.3 Test CB............................................................................. 4-14 4.3.8 Remove blockage.............................................................................. 4-15 4.3.9 Sealing on franking machine (not yet available)................................ 4-15
The FPi 4030 inserting system .................................................................... 5-1

5.1 Transport, storage and installation .................................................................... 5-1 5.1.1 Transport ............................................................................................. 5-1 5.1.2 Unpacking and storage ....................................................................... 5-1 5.1.3 Installation ........................................................................................... 5-3 Mechanical description...................................................................................... 5-5 5.2.1 (Dis)assembly - Covers and plates ..................................................... 5-5 5.2.2 (Dis)assembly - Electrical components ............................................. 5-10 5.2.3 (Dis)assembly - Feeder modules and vertical transport right-hand... 5-15
5.2
Page i6
5.3
5.4
5.2.4 (Dis)assembly - Feeders .................................................................... 5-19 5.2.5 (Dis)assembly - Vertical transport ...................................................... 5-31 5.2.6 (Dis)assembly - Collating area ........................................................... 5-32 5.2.7 (Dis)assembly - Folder ....................................................................... 5-36 5.2.8 (Dis)assembly - Main drive mechanism inserter ................................ 5-50 5.2.9 (Dis)assembly - Envelope feed .......................................................... 5-59 5.2.10 (Dis)assembly - Upper unit................................................................. 5-65 5.2.11 (Dis)assembly - Envelope transport ................................................... 5-73 5.2.12 (Dis)assembly - Envelope sealing and ejection ................................. 5-75 5.2.13 (Dis)assembly - Sensors .................................................................... 5-76 5.2.14 Adjustment ......................................................................................... 5-91 Electrical description ...................................................................................... 5-102 5.3.1 Display board (FPi 4030 only).......................................................... 5-103 5.3.2 Keyboard.......................................................................................... 5-104 5.3.3 Motor relay board ............................................................................. 5-105 5.3.4 Connection board............................................................................. 5-106 5.3.5 Communication board (optional) ...................................................... 5-108 5.3.6 Main board ....................................................................................... 5-112 5.3.7 ID-tag (99.45.04) .............................................................................. 5-118 Maintenance................................................................................................... 5-119
Fault finding ................................................................................................... 6-1

6.1 6.2 6.3 Remotely resolving problems............................................................................. 6-1 Error handling..................................................................................................... 6-2 Error Codes........................................................................................................ 6-3
Upgrading and installing accessories......................................................... 7-1

7.1 7.2 7.3 7.4 7.5 7.6 Conveyer stacker (FPi 4030 only)...................................................................... OMR................................................................................................................... MaxiFeederTM (FPi 4030 only).......................................................................... Online services................................................................................................... Insertn FrankTM (not yet available)................................................................... Intermediate transport ........................................................................................ 7-1 7-1 7-1 7-1 7-1 7-1
Technical Specifications............................................................................... 8-1

8.1 Technical specifications ..................................................................................... 8.1.1 Machine specifications ......................................................................... 8.1.2 Documents ........................................................................................... 8.1.3 Envelopes ............................................................................................ 8.1.3.1 Insert specifications ............................................................. 8.1.4 Capacity feeders and exit options ........................................................ 8.1.5 Fold types............................................................................................. 8-1 8-1 8-3 8-5 8-6 8-7 8-7
Release: 07/2006
0 51.0067.1001.00 Page i7
8.1.6 8.1.7 8.1.8 8.1.9 8.1.10 8.1.11 8.1.12
8.1.13
Processing speed................................................................................ 8-8 Configuration dimensions .................................................................... 8-9 System operation control .................................................................. 8-10 Other general specifications .............................................................. 8-10 Quality ............................................................................................... 8-10 Operating modes .............................................................................. 8-10 Optical Mark Recognition .................................................................. 8-11 8.1.12.1 Concept ........................................................................... 8-11 8.1.12.2 Reading marks and their meaning by level....................... 8-11 8.1.12.3 Format of the Marks.......................................................... 8-12 8.1.12.4 Reading Head Location .................................................... 8-12 8.1.12.5 Options ............................................................................. 8-12 Product customisation per country / organisation ............................. 8-12
9 10
Illustrated parts list....................................................................................... 9-1 Appendix...................................................................................................... 10-1

10.1 10.2 10.3 10.4 Process (paper flow) parts .............................................................................. 10-1 Recommended spare parts ............................................................................. 10-8 Wear parts....................................................................................................... 10-9 Electrical diagrams ........................................................................................ 10-10
11
FPi 4030 Operator Manual.......................................................................... 11-1
Page i8
SERVICE MANUAL FPi 4030 INSERTING SYSTEM This Manual
This Manual
1.1
BRE CCW CW DFC LH OMR RH GUI HMI
Abbreviations
Business Reply Envelope Counter clockwise Clockwise Double Feed Control Left-hand Optical Mark Recognition Right-hand Graphical User Interface Human Machine Interface
1.2
Term Double Feed Control (DFC)
Terminology
Description Double Feed Control is the sensor that 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). Currently DFC's on Francotyp-Postalia 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. Situation in which the top of the sheet is closest to the separation unit in a document feeder. 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. Documents are transported along the vertical track without touching each other. Only after joining the set in the making they do touch each other. 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). Situation in which the bottom of the sheet is closest to the separation unit in a document feeder.
Leading Pane Cycle
Sequential Cycle
Shunting
Trailing
1.3
Release note
This manual is based on service documentation for 70.1 and 62.2 machines, rev. 01.0 - 03/2006, provided by Neopost.
Release: 07/2006
0 51.0067.1001.00 Page 11
SERVICE MANUAL FPi 4030 INSERTING SYSTEM This Manual
Page 12
SERVICE MANUAL FPi 4030 INSERTING SYSTEM Health, Safety and Environment
Health, Safety and Environment

2.1 2.1.1 Safety instructions 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, jewellery, etc. from rotating and moving objects of the system. Switch off the system at the end of the day.
2.1.2
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. The machine is provided with an over-current protection (20 A). It is assumed, however, that the main power supply is provided with a circuit protection as well. 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.
2.2
Symbols on the machine and in the manual
Warning This symbol identifies situations where improper use of the machine can result in personal injury or permanent/catastrophic damage to the machine. This symbol also indicates to consult the operator manual in relation to this action. Warning This symbol indicates a danger caused by high voltage.
Release: 07/2006
0 51.0067.1001.00 Page 21
SERVICE MANUAL FPi 4030 INSERTING SYSTEM Health, Safety and Environment
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 electronic 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 electronic 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. In order to facilitate collection and treatment separated from normal domestic waste, electrical and electronic 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 electronic 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. The manufacturer encourages 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 Francotyp-Postalia dealer.
Page 22
SERVICE MANUAL FPi 4030 INSERTING SYSTEM General description
General description
3.1 The system
The system 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, Fill & Start, FlexFeed, double feed control, hopper swap, multifeed, daily mail, PowerFold, and automatic collator stop positions.
3.2
Denominations
F E A B C D G H I
T
A B C D E F G H I J
Q
K L M N O P Q R S T
J L K J
Envelope catch tray Envelope slide Display with operating buttons Upper unit Locking hand grip upper unit Document feeders Collator arm Collator area Power inlet, power switch Knobs for clearing stoppages
Sensors Bellows Handle for clearing stoppages Water reservoir Side cover (opened) Ruler Thumb wheel for side guide adjustment Side guides envelope hopper Knob for separation adjustment Envelope support bracket
Release: 07/2006
0 51.0067.1001.00 Page 31
3.3
Paper flow
2 5 3
For denomination of all parts, see Section 10.1 Process (paper flow) parts. 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 feeders Document transport Collator Document folder Envelope feeder Insert and exit track
Page 32
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.
Release: 07/2006
0 51.0067.1001.00 Page 33
Page 34
DFC3
FE3
General description
MS3 PH3 77 79
TX
RX
78
80 81
CL3 DFC2 76 75
TX RX RX FE2
PH4 71 70 72
TX
73 74
PH2
DFC1 69 68 64
RX FE1
CL2 PH1 63 65
TX
66 67
TX
So3 PD3 39 62 CL6/7 PD2 PD4 30 So1 45 46 43

RX TX
PH11 31 61 CL5 40 29 32 33 41 35 PH6 CL4 MS1 42 36 14 13 27 11 PH9

RX RX RX
23 CL1
RX
25
MS2 38 44
TX
22
24
26
21
RX
PH10 So2
TX
M1
PH5
TX
37
50 48 47 49
51 52
53 54
56 55
57 58
59
60
PD1 16 18 15 17 9a
TX
20 28 12 34
19
CL8 8 6 9 7
TX
10 PH8
2 5 PH7
M2
For denominations of all parts, see Section 3.3 Paper flow.
3.4.1
Document feeders
The system has three types of feeders. Feeders with: manual separation automatic separation a choice between automatic separation and no separation at all (i.e. daily mail) For the documents to be fed the following rules apply: Documents with the fold types single fold, letter fold, and double parallel fold must be fed with the orientation face up and leading. The address carrying document is to be fed by the highest active feeder. Documents with the fold type zigzag fold must be fed with the orientation face down and trailing. The address-carrying document is to be fed by the lowest active feeder. The feeding process A document is separated by 79 - 81 (feeder 3), 72 - 74 (feeder 2) or 65 - 67 (feeder 1). The document is exited to the vertical track by 77 and 78 (feeder 3), 70 and 71 (feeder 2) or 63 and 64 (feeder 1). The paper transport is monitored by the feeder photocell PH3 (feeder 3), PH2 (feeder 2) or PH1 (feeder 1). The thickness is measured by the thickness measuring unit (DFC unit) DFC3 (feeder 3), DFC2 (feeder 2) or DFC1 (feeder 1). The feeders are mechanically driven from the main motor M2 by a clutch (feeder clutches CL1 - CL3).
3.4.2
Document transport
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. Documents are transported along the vertical track without touching each other. Only after joining the set in the making they do touch each other. The transporting area The vertical track consists of one driven axle per feeder (75, 68, 61), plus one driven axle in the lower vertical track (45). All these axles carry two rollers, except for 75 (at the top feeder),
Sequential Cycle:
Release: 07/2006
0 51.0067.1001.00 Page 35
which carries four rollers. This is necessary for straightening the paper prior to passing the optional reading head. The driven rollers have their counterparts in rollers 76, 69, 62 and 44. If the OMR option is installed, the paper transport prior to entering the reading head (located directly below PH4) is monitored by the reading head photocell (PH4). This monitoring is necessary for establishing the reading window.
3.4.3
Collator
The following rules apply to the way in which a set is collated (i.e. composed): The highest active feeder is processed first, the lowest active feeder last. This is independent of the fold type. If a feeder adds two or more documents to a set (multi-feeding), these documents are first of all processed in the order in which they are separated from the feeder hopper. Based on the actual number of documents from each cycle, the system composes a set based on the minimum amount of cycles and, if possible, a pane cycle in stead of a sequential cycle (see Section 3.4.2 Document transport). In the case of multi-feeding of n documents from the same feeder there are always at least n-1 sequential cycles involved. In the case of OMR processing the document(s) from feeder 3 is/are always processed via sequential cycles. Shunting Note The short shunt is only used for the FPi 2000-2. Shunting is necessary between two successive cycles of the collating process, before a new document joins a partially completed set. During 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). This is necessary to prevent the paper entering from the vertical track from interfering with the partially completed set. The choice between long shunt and short shunt is made in the service menu through the system output selection. In Mode 1 the long shunt is used, in Mode 2 the short shunt is used. The collating area The collating area consists of a set of rollers (46, 50, 53, 56 and
Page 36
60) that can be driven in both directions by the collator motor (M1), and a set of counter rollers (47, 48, 49, 52, 54, 55 and 58). In the reverse direction of the collator motor (M1), documents are fed into the collator area. In the forward direction they are moved out. The entry of the paper into the collator area (not the leaving of paper!) is monitored by the collating area photocell (PH5). The collating process Documents are fed into the collator area from the vertical track, or back into the collator area in the second stage of the shunt process. The documents are aligned against the relevant automatic document stoppers (51, 57 or 59). During shunting, the collator motor (M1) first turns in the forward direction, then in the reverse direction. In case of a long shunt the folding forward clutch (CL4) is activated in the first shunt stage and the folding reverse clutch (CL5) is activated in the second shunt stage (FPi 4030 only). Documents are exited from the collator to the fold unit if a set is complete. In that case both the collator motor M1 (forward direction) and the folding forward clutch (CL4) are activated.
3.4.4
Document folder
The folding process is based on the timed "karate" action of a fold plate (one per fold table). The paper enters a fold table. The flap is turned upwards. The fold plate is turned backwards (from its rest position). The paper is directed into an upward, more or less vertical direction. The fold plate moves forward at the right time and pushes the paper between the pair of upper and lower fold rollers. The fold is located at the place where the paper touches the tangent between the upper and lower fold roller. The timing of the fold plate movement is based on the detection of the paper by the folder input photocell PH6, on machine parameters and on operational fold parameters. The folding process The paper of a completed set leaves the collator area. This is detected by the folder input photocell (PH6). The paper is transported to the first fold table by the fold input rollers (42 and 43). The flap (41) moves up, so paper entering the first fold table will be directed in upward direction. At the appropriate time, the flap (41) moves back and the fold
Release: 07/2006
0 51.0067.1001.00 Page 37
plate (40), which hinges around an axle (39), moves forward. The first fold will be made. Directly after the fold has been made, the fold plate (40) returns to its rest position. This process is controlled by the first fold table clutch (CL6), which drives the curve gear (37), which controls the movement of the fold plate (40) and the flap (41). The axle for the curve gear also carries the brake disc (38), the status of which is monitored by a slotted photocell (SPH3). 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. After leaving the fold rollers (35 and 36), the paper enters the second fold table. The flap (34) moves up, so paper entering 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), which both hinge around axle 31, move forward. The second fold will be made. Directly after the fold has been made, the fold plate (32) returns to its rest position. This process is controlled by the second fold table clutch (CL7), which drives the curve gear (29), which controls the movement of the fold plate (32), the paper guide (33) and the flap (34). The axle for the curve gear also carries the brake disc (30), the status of which is monitored by a slotted photocell (SPH4). 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.
Page 38
3.4.5
Envelope feeder
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 envelope transport subsystem can be manually moved by the right-hand knob, at the left-hand side of the machine. The counter rollers (3, 5, 7, 9 and 12) can be de-coupled from there driven counterparts by a counterclockwise movement of the release handle at the left-hand side of the machine. The envelope feeding process First of all by the action of the feed and separation rollers (1 and 2) an envelope is separated from the stack in the hopper and transported via three pairs of transport rollers (3 - 8). The envelope track photocell (PH7) 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 envelope flap track photocell (PH8). Pulse measurements (measured via slotted photocell SPH1) during the presence of the envelope under the photocells (PH7 and PH8) provide information on the length of the not yet opened envelope, the opened envelope and 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
Insert and exit track
Inserting process 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, for it is fixed between the two rollers (11 and 12). This is a preparation for inserting the document set into the envelope. Now the document set can be inserted. This set leaves the fold
Release: 07/2006
0 51.0067.1001.00 Page 39
unit (transported by rollers 27 plus 28 and by 13 plus 14), is detected by the insert table photocell (PH9) and passes under the fingers before entering the envelope. The insert of the set is considered finished if and when the insert table photocell (PH9) detects the trailing edge of the set. Exiting process Then a number of actions take place: (a) The clutch (CL8) is activated to release the flap and to feed a new envelope to the insert table. (b) The insert table solenoid (So2) is shortly activated, resulting in the ejection roller (16) moving down. (By spring action, after switching So2 off, these driven rollers are pulled high again.) Now the envelope is rejected from the insert table. So2 is deactivated after the complete passage of the filled envelope. The filled envelope passes rollers 17 and 18, the moistening brushes, the sealing track rollers (19 and 20) and the lower sealing roller (22) plus its counter roller (21). Now the photocell (PH11) is triggered. The upper reverse roller (25) is held high (i.e. this roller doesn't contact the lower reverse roller 24) by a spring. A certain time after triggering the PH11 the sealing solenoid (So3) is activated. The envelope is between the upper and lower reverse rollers. By the So3 action the upper reverse roller now is temporarily lowered. Given the turning direction of the lower reverse roller, the transport direction of the envelope is abruptly changed from an "upstream" to a "downstream" direction. Assuming that the trailing envelope edge has passed 21 and 22, this is now the leading edge of the envelope being transported through the sealing rollers 22 and 23. After passing the sealing rollers the envelope is exited to the exit. The photocell (PH11) is restored to its rest position. The exit photocell (PH10) monitors the passing envelope.
Page 310
3.5 3.5.1
Electronics PCB functions
The functions of the PCBs from the schematic overviews can be described as follows:
Board name Function
1 2 3 4a 4b 5 6 7
Display board Key board Motor relay board Connection board Modem board (optional) Communication board (optional) Main PCB ID-tag (99.45.04)
Converts received data into understandable data for the display Contains the start, stop and clear buttons Turns the motor on and off Provides connection to USB, RS232 and the phone line (see note) Converts digital data (from the processor) into analogue data (for external communication) and the other way around Controls the franking interface and external communication Operates the device and controls the user interface 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.
Release: 07/2006
0 51.0067.1001.00 Page 311
3.5.2
Schematic overview
The electronics and the wiring between the boards in the FPi 4030 can be summarized in a schematic overview. For a device without communication board.
Host
FPi 4030 070.1/062.2 / FPi 2000-2

Display board Keyboard USB device Main PCB Switch mode Power supply 24Vdc Motor relay board USB cable Connection board regular
ID Tag
100/115,230V ac
For a device with communication board:
FPi 4030 070.1/062.2 / FPi 2000-2

Display board Keyboard Host USB device Main PCB Communication board USB cable serial
Host Phone RS232 (INF) Connection board Expanded Modem board
Switch mode Power supply ID Tag 24Vdc Motor relay board
100/115,230V ac
Page 312
3.5.3
Software upgrade and backup
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. Concorde is a new application in addition to the FlashOEM application that is used for the RS232 communication. Both applications can run on the same PC. 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.
In Addition to FlashOEM
Release: 07/2006
0 51.0067.1001.00 Page 313
3.5.4
The ID-tag (99.45.04)
Each time the FPi 4030 is started, the presence of the ID-tag (99.45.04) is checked. If the ID-tag (99.45.04) is not present, all software controlled options are switched off. If the ID-tag (99.45.04) 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 Tag and Fram OK Serial number Tag= Serial number FRAM
Yes
TAG count=FRAM count
Yes1
No Define latest counter
TAG correct
No
Copy Tag Counter to FRAM
FRAM correct System blockage error Call Service Copy FRAM Counter to TAG Yes
System de-blockage in service menu OK
Has the ID tag been replaced? Yes5 Set Counter manually (TAG and FRAM)
No4
Synchtonize TAG Counter to FRAM
No
Copy Serial number Tag to FRAM
TAG update flag = ok.
No
Copy Serial number Tag to FRAM
END
Page 314
In this schedule, number 1 to 5 can be described by: 1 2 3 4 5 Normal situation If either FRAM or TAG has been disconnected, the latest counter can be used. PCB or Tag replacement PCB replacement (Tag OK). Tag replacement (new Tag) Note: if incorrect Tag is installed, software controlled options and connectivity will not function correctly.
Release: 07/2006
0 51.0067.1001.00 Page 315
The following information is stored on the ID-tag (99.45.04): Serial number of the machine. Encrypted machine options. Total insert counter (kept up to date when the FPi 4030 is running).
3.5.5
Software package compatibility check
For all systems with (optionally) multiple boards and software versions, Francotyp-Postalia will release packages that contain the supported software versions of each board. The following matrix may be applicable:
Examples Main PCB Communication board
Package 1 Package 2 Package 3
version A version A version B
version A 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.
Page 316
3.6 3.6.1
Optional features Optical Mark Recognition (OMR)
With this option, computer printed documents can be handled fully automatically. 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. If the set contains only one sheet, it is the last sheet. The code must appear in the same location on every page regardless of the actual code length. OMR can be activated by a system specific license code.
3.6.2
Flex Optical Mark Recognition (Flex OMR)
With this option, also non-Francotyp-Postalia OMR codes and alternative document handling algorithms can be recognised in the optical mark recognition process. Flex OMR 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 MaxiFeederTM
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 hopper to the MaxiFeederTM and vice versa. To make use of a MaxiFeederTM it is not necessary to (re-)program the jobs.
3.6.4
Insertn FrankTM (not available yet)
With this option, inline 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.
Release: 07/2006
0 51.0067.1001.00 Page 317
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
Intermediate transport
An intermediate transport kit (not in combination with OMR) for processing 90-115 mm documents from the top feeder can also be ordered.
Page 318
SERVICE MANUAL FPi 4030 INSERTING SYSTEM User interface
User interface
4.1 Operator menus
For an explanation of the Operator menus, see the appropriate Operator Manual.
4.2
Job and Supervisor menus
For an explanation of the Job menu and Supervisor menu, see the appropriate Operator Manual.
4.3
Service menu
See the following flowchart for an overview of the various menus:
Release: 07/2006
0 51.0067.1001.00 Page 41
4.3.1
4.3.1.1
System settings
Configuration
Use this menu to view and change the following options: Intermediate transport Gap separation on feeder 1 OMR reading head installed FLEX OMR dongle installed (FPi 4030 only) Online/INF hardware installed Online services enabled FM connected Modem connected If the configuration, stored in the machine, is updated, the new configuration will be stored after: saving the configuration. switching the machine off and then on. 4.3.1.2 Localisation
Use this menu to set: the language of the operational user interface the service telephone number the document standard size machine type date format Languages English USA, English UK, Dutch, French, German, Spanish, Italian, Katakana, Swedish, Norwegian, Danish, Portuguese, Russian, Hungarian, Czech Document standard size ISO (i.e. metric), Inches, None ISO sizes A4 (297 mm), A5 (148 mm) and A6 (105 mm) for documents; C5 (162 mm) and C6/5 (114 mm) for envelopes Inches 3.5" (90 mm), #9 (99 mm), 4" (102 mm), 6" (152 mm), 7" (178 mm), 8" (203 mm), 8.5" (216 mm), 11" (279 mm), 12" (305 mm) and 14" (356 mm) for documents; #9 (99 mm), #10 (105 mm) and 6x9 (153 mm) for envelopes
Page 42
4.3.1.3
Software versions
This screen gives release information on: the machine software (programmed in the flash memory) for the inserter part, and the optional communications board. Usually both machine software items should be updated simultaneously, using external flash software.
4.3.1.4
Reset data
Use this menu to initialize the system with the default values. In addition all photocells will be readjusted (Therefore, make sure all paper has first been removed from the machine). The stored counter values are not affected.
4.3.1.5
Power up
In this menu you can select (Yes or No) to display the language menu after machine power up.
4.3.1.6
Folder offset
Two timed cams discs are used for the folding process. There is one cam disc for each folding pocket. 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, thus compensating a clutch activation time that deviates from the average value. In the folder offset menu: 1 Select the folder. 2 Set the equivalent shift in the folding position between -20 mm and +20 mm. 3 Process test material to see if corrections in these settings are required. 4.3.1.7 Flap closer offset
Use this menu to adjust the timing of the activation of the sealing solenoid (So3). This function can be used to improve the sealing process. The timing has influence on the position of the filled envelope (with its flap fixed between two rollers) prior to being transported between the sealing rollers. This position can be adjusted between -10 and + 10 mm (with respect to the default envelope position).
Release: 07/2006
0 51.0067.1001.00 Page 43
4.3.2
4.3.2.1
Job settings
System output (FPi 4030 only)
Use this menu to select operating mode Mode 1 or operating mode Mode 2, for each of the jobs. 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 2 focuses on high speed. The differences between the two modes are related to the way the documents of a set are collated. Mode 1 should be used for: a paper thickness of 65 g/m or less a document length of 12 inch or higher Mode 1 should also be used for some unusual customer-specific applications; Mode 2 should be used for all other jobs. Background information: If Mode 2 is being used, the paper transport stops as soon as the document that is to be added to the set has entered the collating area. This is detected by the collator entry photocell. The partially completed set is moved over a short distance to the fold table. This distance is sufficient to prevent the leading edge of the next document being entered from touching the front of the partially completed set. The complete set is aligned against the paper stop, once the last document of the set has entered the collating area. It is then transported to the folding area for further processing. Mode 2 focuses on minimal necessary paper displacement. This implies a higher processing speed, but with the potential risk of longer paper contact between the new entering document and the partially completed set. However, this is not a problem for the usual normal range of paper weights. If Mode 1 is being used, the partially completed set is transported further into the fold table. After each new document that joins the partially completed set this set is aligned against the paper stop. This takes more time, but the paper-to-paper contact occurs over shorter distances. Mode 1 focuses on problem free operation with a wide range of paper types, at some expense of the process speed.
Page 44
4.3.2.2
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. The extent to which the documents do not overlap each other (i.e. the document offset value) can set for each job in the document offset menu. The default value is 50 mm. The document offset can be varied between 20 mm and 75 mm in 1 mm steps.
4.3.2.3
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 set in the BRE (Business Reply Envelope) offset menu. An offset can be switched on or off for all jobs; from 1 to Lng (Fill & Start). 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). The document directly beneath this document must be at least 60 mm 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 (so no Z-fold). The upper document must be shorter than the envelope height.
Release: 07/2006
0 51.0067.1001.00 Page 45
Background information: The BRE offset can be used for a BRE and an enclosure (card) in 1 set. The extra condition is that this enclosure is equal to or smaller than the set address fold and should be placed directly underneath the BRE in the set. The whole BRE offset is based on friction between the documents in a set. Therefore, it is necessary to make use of these conditions to reduce the risk of poor transporting, folding and inserting. In some cases the BRE option is automatically switched off if one or more of the above-mentioned conditions are not met, so it is safe to switch the BRE option on, unless this option will never be used.
4.3.2.4
Secure jobs
Use this menu to secure (i.e. lock) the selected job. This job can not be deleted and can not be changed in the job menu either. However, a locked job can still be copied into another job that can be modified.
4.3.2.5
Flap closer
Use this menu to adjust the timing of the activation of the sealing solenoid (So3) on a per-job basis. This function can be used to improve the sealing process. The timing has influence on the position of the filled envelope (with its flap fixed between two rollers) prior to being 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
4.3.3.1
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. Before readjusting the photocells you must remove all paper from the
Page 46
machine and clean all the sensors (both transmitter and receiver!) of the photocells. After the photocells 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% 4.3.3.2 Digital inputs
The digital input screens show: the real-time status of the three safety switches (MS1, MS2 and MS3) the two folder cam disks (SPH3 & PD3; SPH4 and PD4) the two pulse discs (SPH1 for the main motor M1 and SPH2 for the collator motor M2) Real-time means that a change is reflected in the displayed status. This allows you to easily check the correct operation of the three microswitches. The folder cam discs can also be tested. During testing, the relevant cam disc will move one half cycle, i.e. the cam disc status changes from "open" to "covered" or from "covered" to "open". After pressing two successive times on a test key the cam disc has performed a full cycle and returns to its original position. Both pulse discs can also be tested. Press the Test key to test the pulse disc signal. Both the speed and the quality (duty cycle) will be tested. Detailed information is obtained via the minimum (Min.) and maximum (Max.) value. The speed range should be between 75% and 125%. The Pulse dist. (Duty cycle) value should between 50% and 150%. If this is the case the message 'Good' will be displayed. If this value is out of range, the message 'Bad' will be 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, the mechanical load has to be checked. If it is higher, the pulse disc might be loose.
Release: 07/2006
0 51.0067.1001.00 Page 47
The Pulse dist. (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%.
4.3.3.3
Actuators tests
The actuator can be selected and activated. The motor runs as long as the test key is pressed. If the fingers solenoid is selected, the fingers move forward as soon as the test key is pressed. Only after releasing the test key the fingers will move back to their rest position. The eject rollers and closer solenoids will be activated and after a short time deactivated during one period of test key pressing. During normal operation these three actuators are always activated for a very short time. This test reflects this situation. Testing the envelope track clutch CL6 will result in switching on the motor M1, as well as activating the envelope track clutch. Collator run in: Collator motor runs in the direction of the document stop position when activated. Collator run out: Collator motor runs in the direction of the folder when activated. Folding pocket 1/2: The main motor M1 is switched on. The relevant fold pocket turns a half fold cycle. After two successive key presses, the initial position prior to entering this menu is reached. Feeder clutches: The main motor M1 is switched on and the relevant feeder clutch is activated if the key is pressed. The feeder 3 clutch is only visible in the case of a 2-station version of the machine. The MaxiFeederTM option is only available if the MaxiFeederTM is present. As long as the key is pressed, its motor will run.
4.3.3.4
Run in
This screen has a counter (with default value of 6000) that shows the number of process cycles that will be emulated, with no paper whatsoever present in the machine. After pressing the Start/Stop key, the run in test will start. After each process cycle the counter decrements. The machine stops automatically if the counter value is zero. You can set the counter to a value other than the default value 6000. If the counter value is 1000 or higher, increments are 1000 with a
Page 48
maximum value of 30000. if the counter value is lower than 1000, decrements are 100 with a minimum value of 10. 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. It is also highly recommended to perform the run in test without any documents in the machine. The timing of the actions for a simulated process cycle are fixed, so 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.
4.3.3.5
DFC test
This menu gives information on the DFC unit output voltage of the two or three feeders. The values are real time. If no paper is present in a feeder the DFC voltage should be approximately 4.1 volt. If during the machine start a DFC unit does not "see" paper, the DFC voltage should be about 9.9 volt. The DFC voltage is lower if the DFC unit "sees" paper. The following rules apply: For 65 g/m paper DFC voltage about 0.2 volt lower For 80 g/m paper DFC voltage about 0.25 volt lower For 120 g/m paper DFC voltage about 0.35 volt lower For 160 g/m paper DFC voltage about 0.5 volt lower
Release: 07/2006
0 51.0067.1001.00 Page 49
Touch screen Use the "Test touch screen" button to check if the touch screen is working correctly. 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 exactly correspond with the displayed object, the touch screen should be calibrated. To do this, use the "Calibrate touch screen" button.
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 to zero. The "since installation" counter can be displayed. The "next visit after" counter can be: - incremented in 5000 steps to a maximum value of 6.000.000 steps. - decremented in 5000 steps to a minimum of 5000 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
4.3.5.1
OMR
OMR code definition
This menu allows you to define the OMR-2 reading codes, providing that the machine has OMR enabled. One OMR code can be set for each machine. This code can be used for one or more jobs. The following list shows all system options (customer dependant): Start mark Insert on Divert mark (implemented as a stop mark) (FPi 4030 only) Stop mark (FPi 4030 only) Selective feed (FPi 4030 only) Sequence check (FPi 4030 only) Parity check Safety mark Line spacing Choose between Yes and No (toggling function). The line spacing can be changed in steps of approximately 0,02 millimetre. The Lpi
Page 410
value reflects the number of lines per inch, the millimetre value is the distance between two successive marks.
4.3.5.2
Read-code test
Use this menu to test the OMR reading head (RH1) and, if necessary, to readjust the relevant OMR electronics. The displayed test information is: Mark quality (the quality of the marks: bad, good or very good) 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) 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" The current OMR job settings are used for this test. If this is not the case, the text "Select a job with OMR" appears. 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 "Show marks" 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.
Release: 07/2006
0 51.0067.1001.00 Page 411
SHOW MARKS 1 128 63 1 ESCAPE 2 3
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. Select the info. key to display the information screen. This screen shows additional OMR-related 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. Select the "Test" key to shows the mark quality and the number of read marks from the last processed document. Also the gain of the OMR amplifier is shown.
Page 412
The mark quality is either: Bad: Good: Very good: Mark amplitude < 0.6 V Mark amplitude between 0.6 V and 1.5 V Mark amplitude higher than 1.5 V
Select the info. key to display the information screen. This screen shows additional OMR-related 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.
4.3.6
4.3.6.1
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. At the end of the test the photocells will be re-calibrated. The individual functioning of sensors (e.g. photocells) and clutches (e.g. timing) is not checked. This must be done in the special Photocell, Digital inputs and Actuator test menus. Before starting this test make sure: all paper is removed from the system all covers are closed
4.3.6.2
Error counters
This menu displays the last 40 errors that occurred. Select "clear" to clear all error messages.
4.3.6.3
Last error list
This menu displays a list with the 40 most occurring errors. Select "clear" to clear all error messages.
Release: 07/2006
0 51.0067.1001.00 Page 413
4.3.7
4.3.7.1
Online service
Server port
Use this menu to enter: the IP address of the server the server port of the server 4.3.7.2 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". 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. 4.3.7.3 Test CB
Select Test CB to check the following: the serial port the modem the real time clock Fail or Pass will be displayed for each item depending on the result of the test. Serial port Use this option to check 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). Modem Use this option to detect if: the modem is present. there is a dial tone. Real time clock Use this option to check if: the communications board has a battery, and the battery is working correctly. the communications board clock is working correctly.
Page 414
4.3.8
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: 186 "Illegal configuration" during machine start-up. The user can still access all menus, but the machine will be blocked from running jobs or Fill & Start. 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 have 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 IDtag. 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.
4.3.9
Sealing on franking machine (not yet available)
This option is only available if Insertn FrankTM is set to level 2 or 3. By default, sealing is disabled on the franking machine when an Insertn FrankTM job is selected. This service menu option, allows you to ignore the sealing settings of the franking machine. A warning will be displayed each time the job is started on the inserter (INF:51).
Release: 07/2006
0 51.0067.1001.00 Page 415
Page 416
SERVICE MANUAL FPi 4030 INSERTING SYSTEM The FPi 4030 inserting system
The FPi 4030 inserting system

5.1 5.1.1 Transport, storage and installation 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 and storage
Unpacking The system is unpacked by the haulier. The packing material, including the pallet, is taken along. The unpacking instructions are illustrated in the following figure.
Release: 07/2006
0 51.0067.1001.00 Page 51
remove packing material
Page 52
Storage The system needs to be stored under the following conditions:

Storage temperature: Humidity: 10 to 40 C (50 to 104 F) 30 to 80%
5.1.3
Installation
Warning Only an approved installer is allowed to install the system. Make sure that you are fully aware of all the safety aspects before you install the system. 1 2 Connect the power cables. Attach the feeder trays.
3 4
Check the feeder adjustments. Attach the envelope tray (optional).
A
5 Check the envelope adjustments.
Release: 07/2006
0 51.0067.1001.00 Page 53
Fill the water reservoir.
Moisten the brushes.
8 9
Switch the system on. Check the localization menu (service menu/system settings/ localisation) for the Sales Organisation and country specific details. 10 Perform a Fill & Start job to check the correctness of the - Fold mm (or adjust the folder offset in the service menu). - Flap closer quality (or adjust the flap closer offset in the service menu). 11 Configure alternative options based upon the requirements. See Section 7 Upgrading and installing accessories.
Page 54
5.2 5.2.1
Mechanical description (Dis)assembly - Covers and plates
Right-hand side cover
RH
LH
To disassemble the right-hand side cover: 1 Open the upper unit by lifting the hand grip (2). 2 Remove (loosen) the six screws of the right-hand side cover (1). 3 To remove the cover, turn and move as shown in the figure.
Release: 07/2006
0 51.0067.1001.00 Page 55
Left-hand side cover
RH
LH
To open the left-hand side: 1 Open the upper unit (1) and the hinged cover (4). 2 Remove (loosen) the two screws of the Left-hand side cover (2). 3 Remove the two screws and loosen one screw of the inner cover (3).
Page 56
Top cover feeders, covers collator area, power supply cover
RH
LH
3 4
Release: 07/2006
0 51.0067.1001.00 Page 57
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 two screws of the bottom plate (4) and remove the bottom plate.
Page 58
Covers upper unit
RH
LH
To easily access the interior, open the covers in the following order: 1 Vertical transport cover (4) 2 Top covers (1, 2, and 3) 3 Loc cover (5)
Release: 07/2006
0 51.0067.1001.00 Page 59
5.2.2
(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 (99.45.04). See Section 3.5.4 The ID-tag (99.45.04). If the board is new to the system, the error message INS: 186 will be displayed, which indicates that the serial number in the ID-tag (99.45.04) 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 4.3.8 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.
Page 510
Main board
LH
To disassemble the main board: 1 Disconnect the wiring to the main board (1). 2 Remove the screw (2). 3 Lock washer and spacer. 4 Carefully pull the main board from the board holders as shown.
Release: 07/2006
0 51.0067.1001.00 Page 511
ID-Tag Ordering and installing new ID tag: When the ID tag fails, the system can continue running without using OMR or Insertn FrankTM 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.
Page 512
Display board (FPi 4030)
1 4 2
LH
Before removing the display (2) or the display board (3), the complete display bracket must be removed from the system. 1 Remove the top cover (1). 2 Remove the two screws that hold the bracket to the system. 3 Disconnect the display cable (4). 4 Withdraw the display bracket carefully. 5 Disconnect the wiring (5 and 6) so that the display board can be removed. 6 Carefully remove the display board.
Release: 07/2006
0 51.0067.1001.00 Page 513
LH
To remove the display: 1 Remove the four screws (3) which secure the display (2) to the mounting bracket display (6). 2 Withdraw the display (2) carefully. Note Connect the wiring before replacing the display. Be sure to replace the four spacers (5).
Page 514
5.2.3
(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.
6 1 2 5 3 4
RH
Release: 07/2006
0 51.0067.1001.00 Page 515
Drive mechanism right-hand - Belts and pulleys
2 3 4
RH
Belt 4 1 Slacken the two screws of the belt tensioner (5). 2 Shift the belt tensioner downwards. 3 Remove belt 4 from the pulleys. Pulley 1 1 Loosen the main belt, PJ belt and drive belt inserter. 2 Remove the spring clip. 3 Slide the main pulley off the axle. Pulleys 2 and 3 Pulleys 2 and 3 are "snapped" to their cyl. pins. They can be removed by pulling them off the axle.
Page 516
12 13 14
RH
Belt 4 1 Slacken the hexagonal head screw of the belt tensioner (1). 2 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 off the axle. Pulley 8 1 Remove the hexagonal head screw of the belt tensioner (2). 2 Withdraw the tensioner. 3 Slide the pulley 5 from the axle. 4 Remove the cyl. pins from the axle. 5 Slide pulley 8 off the axle.
Release: 07/2006
0 51.0067.1001.00 Page 517
Drive mechanism left-hand

1 2
LH
Belt 1 Unhook the tension spring (2) from the inside frame. 2 Remove belt 1 from pulley 3. Clutch and Pulley 1 Disconnect the wiring of the clutch. 2 Remove the spring clip (6). 3 Slide the clutch (5), the disc (4), and the pulley (3) off the axle.
Page 518
5.2.4
(Dis)assembly - Feeders
All the feeders are provided with dividable drive axles. Removal of the complete feeders: 1 Remove the hoppers. 2 Remove the extension part of the drive axle (9, refer to the following figure). Take care that it is a left side screw-threaded axle end. Each feeder can now be removed separately. 3 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. Top feeder (feeder 3)
RH LH
10
To loosen the top feeder: 1 Unhook the tension spring (7) from the screw (8) (on the righthand side of the feeder). 2 Disconnect the wiring of the feeder. 3 Cut the wire straps. 4 Remove the wiring from the left-hand inside frame.
Release: 07/2006
0 51.0067.1001.00 Page 519
5 6 7 8
Remove the spring clip (1), clutch (2), belt (4), and pulley (3) of the top transportation axle. Unhook the tension springs (5) from the inside frame. Remove the screw of the left-hand and right-hand hinge pin (6) of the top feeder. Remove the top transportation axle (10) by moving it in the righthand direction.
RH
B A
LH
To remove the feeder: 1 Move the feeder a bit downstream as indicated (A). 2 Lift the right-hand side of the feeder first. 3 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.
Page 520
Middle feeder (feeder 2)
RH
11
10 9
LH
To loosen the middle feeder: 1 Unhook the tension spring (2) from the screw (1) (on the righthand side of the feeder). 2 Disconnect the wiring of the feeder. 3 Cut the wire straps. 4 Remove the wiring from the left-hand inside frame. 5 Remove the spring clip, clutch (9), belt, and pulley of the middle transportation axle. (Remove axle to the right-hand side.) 6 Unhook the tension spring (10) from the inside frame. 7 Remove two hexagonal heads. 8 Remove the guide plate (5). 9 Remove the screw of the left-hand and right-hand side hinge pin (11) of the middle feeder.
Release: 07/2006
0 51.0067.1001.00 Page 521
RH
* )
LH
To remove the middle feeder: 1 Move the feeder a bit downstream (A). 2 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.
Page 522
Lower feeder (feeder 1)
LH
RH
"
$ % &
To loosen the lower feeder: 1 Unhook the tension spring (2) from the screw (1) (on the righthand side of the feeder). 2 Disconnect the wiring of the feeder. 3 Cut the wire straps. 4 Remove the wiring from the left-hand inside frame. 5 Remove the spring clip (7), clutch (6), belt (8), and pulley (5) of the lower transportation axle. (Remove axle to the right-hand side.) 6 Unhook the tension spring (4) from the inside frame. 7 Remove the two screws of the left-hand and right-hand side hinge pin (3) of the lower feeder.
Release: 07/2006
0 51.0067.1001.00 Page 523
RH
* )
LH
To remove the lower feeder: 1 Move the feeder as far as possible downstream (A). 2 Remove the feeder by turning it out of the machine as indicated (B). Note Be careful when replacing feeder 1, the hinge pin at the RH side is locking the ball bearing.
Page 524
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.
!
LH
RH
" $ #
To remove cover 1 to 4: 1 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 57). 2 Pull cover 1, 2 and 3 backwards on the right-hand side and pull it out on the left-hand side. 3 Loosen the screws (6) at cover 5. 4 Remove the cover. 5 Pull cover 4 backwards on the right-hand side. 6 Pull it out on the left-hand side.
Release: 07/2006
0 51.0067.1001.00 Page 525
Rubber paper pullers
RH
B
A C
LH
To remove the rubber paper pullers: 1 Remove the feed axle assy. (2) in the right-hand side direction (A) until the left-hand side is clear from the axle (1). 2 Tilt the axle assy. (2) at the left-hand side (B) and withdraw the right-hand side off the axle from the hole in the feeder frame. 3 Remove the axle assy. as indicated (C). 4 Hold the plastic cover (3) in place with one hand and push firmly against the rubber paper puller as indicated (D). 5 Rotate the axle 180 degrees and push again. Repeat the rotating and pushing until the paper puller can be pulled off 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.
Page 526
Pulley of paper puller axle
RH
LH
1
To remove the pulley of the paper puller axle: 1 Remove the feed axle assy. as described in Section Rubber paper pullers on page 526. 2 Remove the axle from the plastic cover. 3 Push the rubber paper puller off the axle. 4 Remove the spring clip, the washer and the bearing. 5 Push the pulley assy. to the left to release it from the cyl. pin. 6 Remove the cyl. pin. 7 Slide the pulley assy. off the axle.
Release: 07/2006
0 51.0067.1001.00 Page 527
Upper separation roller Note The feeder unit does not need to be removed for replacing separation rollers.
Grease
RH
Push A
LH
2
To remove the upper separation roller: 1 Remove the feed axle assy. as described in Section Rubber paper pullers on page 526. 2 Click the plastic cover (2) off the axle (A). 3 Remove it with the belt and the paper pulleys from the feed axle. 4 Remove the grease from the left hand side of the feed axle with some alcohol. 5 Push the feed roller (1) to the left hand side off the axle as indicated. 6 Rotate the axle 180 degrees and push again. 7 Repeat the rotating and pushing until the feed roller can be pulled off the axle. 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 this figure. Replace the plastic cover with the belt and the rollers.
Page 528
Lower separation roller Note The feeder unit does not need to be removed for replacing separation rollers.
1 2
RH
LH
To remove the lower separation roller: 1 Remove cover 3 as described in Section Automatic separation feeder (with daily mail) on page 525. 2 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). 3 Move the axle assy. (2) downwards side and withdraw the righthand side of the axle from the hole in the feeder frame.
Release: 07/2006
0 51.0067.1001.00 Page 529
Slide the roller (1) off the axle assy. (2) as shown in the following figure. 1 2
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 Remove the spring clip securing the gear 64T. 2 Lift the feeder. 3 Slide the gear 64T off the axle.
Page 530
5.2.5
(Dis)assembly - Vertical transport
RH
LH
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 59.
Release: 07/2006
0 51.0067.1001.00 Page 531
5.2.6
(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 Remove the collator area covers as described in Section Top cover feeders, covers collator area, power supply cover on page 57. 2 Disconnect the wiring of the collator motor.
Page 532
Loosen the set screw (7) on the bush (6) as shown in the following figure.
LH
4 5 6 7
Pull the motor out of the frame. Support the collating arm. Remove the screws (1) as shown in the figure above (two at the left-hand side and two at the right-hand side). Carefully remove the collating arm.
Release: 07/2006
0 51.0067.1001.00 Page 533
Collator stops (FPi 4030 only)
RH
LH
5
To remove the collator stop motor: 1 Remove the plate with clips attached (1). 2 Remove the moving arm (2). 3 Remove the gear wheel (3). 4 Disconnect the collator stop motor wiring. 5 Remove the two screws (4) that hold the collator stop motor in place, and carefully remove the motor (5).
Page 534
Belts
8 9 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 Remove roller 1 from the axle. 2 Slide the axle to the left-hand side out of the bearings. Take care of the tensioner (2), it is spring loaded. 3 Remove the tensioner (2). 4 Remove the plate (3). 5 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 Remove the accompanying spring clips and washers. 2 Slide the guide rollers off the axles. 3 Remove the screw of the axle of the guide roller (9). 4 Slide the axle to the left-hand side. 5 Remove the spring clip at the right-hand side of the guide roller. 6 Slide the roller off the axle.
Release: 07/2006
0 51.0067.1001.00 Page 535
5.2.7
(Dis)assembly - Folder
Right-hand drive mechanism Lower folder section
RH
4 3 2 1
Belts: The removal of the drive belt (1) is described in Section Drive mechanism right-hand - Belts and pulleys on page 516. Pulleys: 1 Remove the drive belt (1). 2 Remove the accompanying spring clip. 3 Remove the clamping ring. 4 Slide pulley 2 and 3 off the axles.
Page 536
Gears: The gears, number 4 (picture on page 536) and number 1 (following picture), can easily be slid off the axles. Take care of the cyl. pins when removing the gears.
RH
Release: 07/2006
0 51.0067.1001.00 Page 537
Upper folder section
RH
1 2
4 5
6 10 9 8 7
Belts: 1 Slacken the two screws (2) of the belt tensioner (1). 2 Remove the belt (5) from the pulleys (3 and 6). Pulleys: 1 Remove the belt (5) as described in the previous section. 2 Remove the spring clip and the washers of the pulley (3). 3 Slide the pulley off the axle. 4 Slacken the set screw (4) of the pulley (6). 5 Slide the pulley off the axle.
Page 538
Gears 8 and 10: 1 Remove the spring clip, clamping ring and washers. 2 Remove the gears (8 and 10). When removing gear 8, take care of the cyl. pin. Gear 9: 1 Remove the belt (5). 2 Remove the pulley (6). 3 Remove the spacer (7). 4 Remove gear 9.
Release: 07/2006
0 51.0067.1001.00 Page 539
Left-hand drive mechanism Gears
LH
5 4 3 2 1
To remove the gears of the lower folder section (1 to 5) at the lefthand side of the machine: 1 Remove the circuit board. 2 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. 3 Remove the gears (1 to 5).
Page 540
Fold mechanism
12 3 4 5 6 7 8 9
RH
10
11 12
13 14
17
16
15
The fold plates (1 and 5) are driven via the curved gears (6, four in total) and two gears (3), activated by the two clutches (2) on the drive axle (4).
Release: 07/2006
0 51.0067.1001.00 Page 541
Gears 32T, drive axle 1 Remove the belt (13), pulleys (12 and 14) and freewheel clutch (11). 2 Remove the locking plate (10) securing the bearing of the drive axle (4).
LH
RH
3 4
5 6
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. Remove the bearing, spacer, washers and the spring clip of the left-hand side of the drive axle assembly. Slide the gear (1) off the axle.
To remove the gear (4) and clutches (2 and 3): 1 Cut the wire straps at the connectors of the clutches. 2 Slide the clutch (2) to the left-hand side of the axle. Take care of the cyl. pin of the clutch. 3 Remove all the components between the clutches, including the cyl. pin of the clutch (3). 4 Slide the clutch (3) to the left-hand side off the axle. 5 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.
Page 542
Curved folder gears 1 Remove the drive axle assembly as described in Section Gears 32T, drive axle on page 541 (refer to the picture on the same page). 2 Remove the bearings (9) from the axles (6). 3 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
5 6 7
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)
Release: 07/2006
0 51.0067.1001.00 Page 543
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. 10 Carefully lift each complete fold assembly upwards and withdraw it. First curved folder gears
8 9
RH
3 4 5
LH
7 6
9 10
RH
11 12 13 14 15
LH
17 16
Page 544
To remove the curved gears: 1 Remove the two screws (6). 2 Slide both hinge plates (5 and 7) together with the fold plate (4) off the axle. 3 Pull the curved gears (2 and 8) off the axle. Second curved folder gears Refer to the figure on page 544. 1 Remove the hinge plates (15 and 17) in the same way as described previously. 2 Pull the curved gears (9 and 10) off 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 544). See Section Paper guide on page 596.
Release: 07/2006
0 51.0067.1001.00 Page 545
Rollers Input rollers Remove the drive belt as described in Section Drive mechanism right-hand - Belts and pulleys on page 516.
LH
1 2
RH
To remove the input rollers: 1 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 536. 2 Remove the bearing locking plate (3).
Page 546
2 3
RH
6 7
LH
9
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 lefthand 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.
Release: 07/2006
0 51.0067.1001.00 Page 547
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 597.
Page 548
Upper fold rollers
RH
"
LH
To remove the upper fold rollers: 1 Remove the belt with the pulley (5) and the three gears (4) at the right-hand side. 2 Remove the guide strip (2). This is necessary for the removal of the first fold roller. 3 Remove the bearing locking plates (3) on both sides. 4 Move roller 1 to the right-hand side until the left-hand bearing is free of the left-hand frame. 5 Move the left-hand side of the roller downwards and withdraw the roller out of the right-hand frame. Note For belt adjustments, see Section Drive belt upper folder section. page 595.
Release: 07/2006
0 51.0067.1001.00 Page 549
5.2.8
(Dis)assembly - Main drive mechanism inserter
RH
8 7 6 5 4 3 2 1
The main motor 8 provides the mechanical power to the FPi 4030, with exception of the collating area and the collator stops.
Page 550
Belts PJ-belt For removal of the PJ-belt (2): 1 Disassemble the main drive belt for the feeder and folder section. See Section Drive mechanism right-hand - Belts and pulleys on page 516. 2 Loosen the two hexagonal head screws (4) of the tensioner (5). 3 Remove the belt (2) from the main pulley (1) and the motor pulley (3). Drive belt inserter
12 3 4
RH
14
13 12 11
10
All moving components of the inserter part are driven by belt 10. To remove belt 10: 1 Loosen the two hexagonal head screws of the tensioner (1). 2 Remove the belt from the pulleys.
Release: 07/2006
0 51.0067.1001.00 Page 551
Belt envelope feed
"
&
'
40
! "
' & %
$ #
To remove the belt envelope feed: 1 Remove the support plate (11) by which the intermediate axle (13) is supported. Take care of the bearings and the washers. 2 Remove the belt (5) from the pulley on the intermediate axle and from the pulley on the envelope feed axle (3).
Page 552
Pulleys Refer to the figure on page 551. Pulleys 5 and 9 1 Remove the spring clips of the pulleys (5 and 9). 2 Remove the pulleys (5 and 9). Pulley 11 1 Remove the main pulley (refer to Section Drive mechanism right-hand - Belts and pulleys on page 516). 2 Remove the pulley (11). Pulley 8 1 Remove the mounting plate (6) with the adjustment plate and the pulse disc sensor. 2 Remove the pulse disc (7). 3 Slide the pulley (8) off 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 552. Pulley 9 1 Remove the belt (5) as described in . 2 Remove the accompanying spring clip and washer of the pulley (9). 3 Slide the pulley (9) of the envelope feed axle (3). Pulley 14 1 Remove the bearings, washers and gears from the intermediate axle (13). 2 Tap the tension pin from the intermediate axle. 3 Slide the pulley (14) off the axle. Gears Refer to the figure on page 551. Gears 3 (sealing rollers) 1 Remove the pulley (5). 2 Remove the spring clips and washers. 3 Slide the gears (3) off the axles. Gear 2 The gear (2) is mounted to the axle by a tension pin. To remove the gear (2):
Release: 07/2006
0 51.0067.1001.00 Page 553
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 Remove the pulse disc (7) and the pulley (8). 2 Remove the spring clip at the left-hand side of the axle. 3 Slacken the set screws of the two rollers. 4 Remove the locking plate (13). 5 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. 6 Tap the tension pin. 7 Dissemble the gear. Gear 12 1 Removal of the pulley (9) 2 Slide the gear (12) off the axle. Refer to the figure on page 552. Gears 8, 10, 15, 16, 18, 20 and 22 1 Remove the spring clips and washers. 2 Remove the gears (8, 10, 15, 16, 18, 20 and 22). Gear 21 1 Remove the nuts. Take care of the tension spring. 2 Slide all the parts of the brake rod. 3 Remove the gear (21). For adjustment of the friction brake, see Section Friction brake on page 5100. Gear 6 1 Remove the gear (8). 2 Dissemble the clutch (7). 3 Remove the support plate (11). 4 Disconnect the wiring of the clutch. 5 Slide the clutch off the axle. 6 Remove gear 6.
Page 554
Gears 4 and 12 1 Remove the support plate (11) to free the intermediate axle (13) with its components. 2 Remove the bearings, washers and spring clip from the axle. 3 Slide the gears (4 and 12) from the axle. Gear 17 1 Remove the insert table to get access to the transportation axle. 2 Remove the spring clip, washer and bearing at the left-side of the transportation axle (2). 3 Move the axle a little to the right-hand side. 4 Slide the gear (17) to the left-hand side. 5 Remove the cyl. pin. 6 Slide the gear (17) off the axle. Gear 19 The gear (19) is mounted to the transportation axle (1) by a tension pin. To remove this gear: 1 Remove the insert table. 2 Remove the spring clip, washer and bearing from the left-hand side of the axle. 3 Slide the rollers to the right-hand side to remove the cyl. pins. 4 Slide the axle to the right-hand side out of the right-hand inside frame. Take care of the two rollers. 5 Tap the tension pin. 6 Remove the gear (19) from the axle. Clutches Slip clutch envelope feed axle Refer to the figure on page 552. 1 Remove the metal ring of the pulley (9). 2 Slide the belt (5) of the pulley (9). 3 Remove the pulley from the axle. 4 Slide the slip clutch off the axle. 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 552 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 Remove the support plate (11) and the gear (8). 2 Disconnect the wiring of the clutch. 3 Slide the clutch (7) off the axle.
Release: 07/2006
0 51.0067.1001.00 Page 555
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 Remove the main lead. 2 Remove the power supply cover (2). 3 Disconnect all wiring. 4 Cut the wire straps.
Page 556
LH
7 5
6
6 4 5 4 7 Remove the two countersunk head screws (1) and the two round head screws (2) securing the power supply assy. Pull the power supply assy. out of the machine.
Note When replacing the power supply assy., ensure that the guide plates 1 (refer to the figure on page 556) are fitted correctly in the guide rollers. Also take care to fit the microswitch correctly and ensure the correct functioning.
Release: 07/2006
0 51.0067.1001.00 Page 557
Main motor M2
RH
8 7 6 5 4 3 2 1
To remove the main motor: 1 Release the belt tensioner (5) 2 Remove the belt (2). 3 Remove the bottom plate of the machine. 4 Remove the four screws (6) and the washers (7). 5 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 91, and Section Main drive belt inserter on page 593.
Page 558
5.2.9
Hopper O-rings
(Dis)assembly - Envelope feed
RH
13 12 11
LH
10 9 8 7 6 5 4 3 2 1
To remove the O-rings: 1 Move the side guides to the widest position. 2 Remove the centre front plate (9). 3 Remove the three screws (1) at the left-hand side and the three screws (11) at the right-hand side of the hopper assembly (10). 4 Withdraw the hopper assembly (10) from the machine. 5 Remove the pulley (13) and slip clutch (12) as described in Section Pulleys on page 553. 6 Remove the spring clips, washers, and bearings from the envelope feed axle (5). 7 Remove the axle from the machine. 8 Slide the O-rings (7) from the joggers (6).
Release: 07/2006
0 51.0067.1001.00 Page 559
Separation roller Note Before removing the separation roller, first check the adjustment procedure as described in Section Separation roller on page 5
99.
Refer to the figure on page 559. 1 Remove the centre front plate and the hopper assembly as described in the previous paragraph. 2 Slacken the two screws (3) and remove the separation spring (2) with the separation roller. 3 Remove the separation axle with roller from the separation spring. 4 Slacken the set screw of the separation roller (4). 5 Slide it off the separation axle. Feed roller Refer to the figure on page 559. 1 Remove the feed axle as described in Section O-rings on page 559. 2 Remove a jogger from the envelope feed axle. 3 Slacken the set screw from the feed roller (8). 4 Slide it off the axle. Note On replacement of the joggers and/or feed roller, position the feed roller in the middle of the shaft and the removed joggers between the "forks" of the side guide. Take care to reassemble the rings between fork and jogger. Ensure that the set screws of the feed roller are tightened onto the groove of the feed shaft.
Note For adjustments, see Section Separation roller on page 599.
Page 560
Envelope track Lower rollers
1 2 3 4 5
7 8
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 off the axle. Take care of the pressure spring of the bearings.
Release: 07/2006
0 51.0067.1001.00 Page 561
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. .
2 3 4 5 6 7 8 9 1011
RH 12 13 14
22 21 LH
18 17 16 15 20 19
6 7 Remove the flap scraper (21). Remove the pressure springs of the bearings of the fourth set of rollers (19). 8 Slide the rollers to the left-hand side to remove the cyl. pin. 9 Remove the spring clips. 10 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 5101.
Page 562
Upper rollers Refer to the figure on page 561. 1 Remove the insert table as described in Section 5.2.11 (Dis)assembly - Envelope transport" on page 573. 2 Slide the first set of rollers (5) off the axle (7). 3 Remove the cyl. pins (4). 4 Remove the spring clip (1), washer (2) and bearing (3) at the left-hand side of the axle (7). 5 Slide the axle to the right-hand side. 6 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 562. 1 Remove the insert table to get access to the fourth set of rollers of the envelope track. 2 Remove the fixing plate envelope track (8, figure on page 561) to get more room. 3 Slide the rollers aside to remove the cyl. pins. 4 Remove the spring clip, washer and bearing at the left-hand side of the axle. 5 Slide the axle to the left-hand side. 6 Remove the rollers from the axle. Rubber roller Refer to the figure on page 562. 1 Remove the insert table and the transportation table (19). See figure on page 573. 2 Slide the transportation table in the direction as indicated, over the second fold roller. 3 Remove the knob (1) and the spring clips (5) of the rubber roller (11). 4 Remove the gear at the right-hand side of the rubber roller as described in Section Gears on page 553. 5 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. 6 Lift the right-hand side. 7 Withdraw the rubber roller from the machine.
Release: 07/2006
0 51.0067.1001.00 Page 563
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 597.
Page 564
5.2.10 (Dis)assembly - Upper unit

Drive mechanism The drive mechanism of the upper unit is located at the right-hand side of the machine.
LH
1
4 5 6 7 8 9
10
RH
Belt 1 Slide the belt (8) of the pulley (7). 2 Remove the belt from the pulley (10).
Release: 07/2006
0 51.0067.1001.00 Page 565
Pulleys Pulley 10: 1 Remove the spring clip of the pulley (10). 2 Slide the pulley (10) from the axle. Pulley 7: 1 Remove the axle (5) completely. 2 Open the upper unit. 3 Remove the six screws by which the brake plate (2) is mounted to the upper frames. Take in account the weight of the upper unit when removing the dampers. 4 Close the upper unit and remove the axle (1). 5 Move the brake plate (2) with assembled components carefully aside. Take care of the wiring to the solenoid, the sensor and display. 6 Remove the plate (3). 7 Remove the spring clips of the axle (5). 8 Slide the rollers off the axle (5) aside. 9 Remove the two cyl. pins. 10 Slide the axle to the right-hand side out of the right-hand frame. Take care of the rollers, washers and bearings. 11 Tap the tension pin of the gear (9). 12 Slide the gear off the axle. 13 Remove the pulley (7) from the axle. Gears Gear 9: See the previous section (pulley 7). Gear 6: 1 Remove the brake plate as described in the previous section (pulley 7). 2 Remove the spring clips of the axle (4). 3 Remove the cyl. pins of the rollers. 4 Slide the axle (4) to the right-hand side out of the frame. 5 Tap the tension pin of the gear (6). 6 Slide the gear (6) off the axle.
Page 566
Document inserting
1 2 3 4 5 6
RH
LH
12
11
10
Rollers 1 Remove the guide plates (1) on both sides. 2 Slide the upper insert rollers (3) off the axle. Take care of the cyl. pins. 3 Slide the first set of ejection rollers (11) off the axle. Take care of the cyl. pins.
Release: 07/2006
0 51.0067.1001.00 Page 567
RH
LH
To remove the second set of ejection rollers: 1 Remove the spring clip (5). 2 Remove the roller (4) from the axle. 3 Remove the spring clip (2). 4 Slide the axle to the left-hand side. 5 Tap out the cyl. pin of the roller (1) and slide the roller from the axle. Gears Refer to the figure on page 567. 1 Remove the guide plates (1) on both sides. 2 Remove the bracket 6 and the sensor. Take care of the wiring of the sensor. 3 Remove the pulley (5) and the spring clip (12). 4 Slide the outer bearings at the axle (8). 5 Remove the tension springs (2). 6 Slide the axle (8) with complete insert assembly through the slotted holes out of the frames.
Page 568
RH
LH
11
10
Refer to the figure above. 1 Remove the frame plate (5). 2 Slide the gears (4, 7 and 8) off the axles. Take care of the pressure springs (6).
Release: 07/2006
0 51.0067.1001.00 Page 569
8 7
Refer to the figure on page 567. 1 Remove the screws (7). 2 Withdraw the complete ejection assembly (9) together with the draw bar and the attached plunger (1), from the frames. Take care of the washers and the pressure spring of the plunger. Refer to the figure on page 569. 1 Remove the frame plate (9). 2 Slide the gears (10 and 11) from the axles. Ejection solenoid Refer to the figure on page 569. 1 Remove the covers of the loc, to get access to the solenoid. See Section Right-hand side cover on page 55. 2 Disconnect the wiring of the solenoid. 3 Remove the two screws (3). 4 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 597.
Page 570
Envelope transport and sealing
RH
5 4
Release: 07/2006
0 51.0067.1001.00 Page 571
LH
Rollers Sealing transport rollers 1 Open the upper unit. 2 Remove the spring clips off the axle (6). 3 Slide the transport rollers (4) off the axle. Take care of the pressure springs (5). Lower reverse rollers Refer to Section Pulleys on page 566. Upper reverse rollers 1 Remove the accompanying spring clips and washers. 2 Slide the rollers (7) off the axle. Sealing solenoid 1 Disconnect the wiring of the solenoid 1. 2 Remove the screws (2). 3 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 597.
Page 572
5.2.11 (Dis)assembly - Envelope transport
5 6 7
8 9 10 11 12
13
14 15 16
RH
Lower ejection rollers 1 Remove two screws (13) of the insert table (19) and four screws (1) of the insert table (2). 2 Remove the drive belt inserter as described in Section Drive belt inserter on page 551.
Release: 07/2006
0 51.0067.1001.00 Page 573
LH
22 21
1 2
20 19
18 17
3 4 5 6 7 8 9
Remove the locking plate of the bearing at the right-hand side of the transportation axle (20). Slide the axle (19) 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.
Page 574
Sealing track transportation rollers Refer to "Section Pulleys" on page 553 and to the figure on page 551. 1 Remove the pulse disc (7). 2 Remove the pulley (8) from the pulse disc axle (14). Refer to the figure on page 573. 1 Remove the pressure springs (11) from the bearings (12) of the axle (8). 2 Slide the rollers (4) aside to remove the cyl. pins (3). 3 Remove the spring clip, washer and bearing at the left-hand side of the axle. 4 Slide the rollers off the axle. Note Take care of the pressure springs (10) when replacing again. On the left-hand side a spring with lower force than on the right-hand side has to be fitted.
5.2.12 (Dis)assembly - Envelope sealing and ejection

Upper sealing roller Refer to the figure on page 573. 1 Remove the gear at the right-hand side of the sealing roller (6). Refer to Section Gears on page 553. 2 Remove the pressure springs (11) from the bearings (12) and the spring clip at the left-hand side of the sealing roller. Take care of the washer (10) and the spring (9). 3 Move the sealing roller (6) to right-hand side to free the left-hand bearing from the left-hand inside frame. 4 Withdraw the upper sealing roller. Lower sealing roller Refer to the figure on page 573. 1 Remove the upper sealing roller. Refer to the previous section. 1 Remove the gear at the right-hand side of the sealing roller (5). Refer to Section Gears on page 553. 2 Remove the two screws (14) and the mounting plate (7). 3 Remove the spring clip, washer and bearing at the left-hand side of the lower sealing roller (5). 4 Move the sealing roller to the right-hand side. 5 Withdraw the lower sealing roller.
Release: 07/2006
0 51.0067.1001.00 Page 575
5.2.13 (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 Remove the right-hand side cover. 2 Cut the wire strap. 3 Remove the bracket (2) together with the safety switch (1). 4 Remove the safety switch from the bracket.
Page 576
Safety switch LH side cover
LH
1 2 3
The safety switch is located at the left-hand side of the machine near the sealing rollers. To remove the safety switch (3): 1 Open the left-hand side cover. 2 Remove the cover (1). 3 Remove the safety switch (3) from the bracket (2).
Release: 07/2006
0 51.0067.1001.00 Page 577
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 Remove the supply cover. 2 Remove the safety switch (2) from the frame (1).
Page 578
DFC and photocells Note Whether or not photocells are replaced, it is advised to reset the photocells after finishing servicing. Feeders
3
RH
2 1
LH
Each feeder is equipped with a DFC. To remove the DFC: 1 Remove the covers (1, 2, 3 and 4). Refer to Section Rubber paper pullers on page 526. 2 Remove the guide plate (5), when removing the DFC of the feeder (2). Refer to Section Middle feeder (feeder 2) on page 521. 3 Disconnect the wiring of the DFC. 4 Remove the screw (2) securing the DFC (3) to the bracket (1).
Release: 07/2006
0 51.0067.1001.00 Page 579
LH
RH
"
LH RH
Feeder photocells Transmitter (LED) 1 Remove the bracket (4) with the transmitter (3). 2 Disconnect the transmitter. 3 Remove the transmitter from the bracket. Receiver (Sensor) 1 Remove the bracket (2) with the sensor (1). 2 Disconnect the sensor. 3 Remove the sensor from the bracket.
Page 580
Vertical transport
1 2 3 4
Vertical transport photocells (optical, only with OMR). In the 2,5 stations version, the detectors are located beneath the upper vertical transport rollers. Transmitter (LED) 1 Open the loc. 2 Remove the guide plate (1) with the assembled transmitter (2). 3 Disconnect the wiring of the transmitter. 4 Remove the transmitter. Receiver (Sensor) 1 Remove the vertical transport cover. 2 Cut the wire strap securing the wiring of the sensor (3) to the bracket (4). 3 Remove the bracket with the sensor. 4 Disconnect the wiring. 5 Remove the sensor.
Release: 07/2006
0 51.0067.1001.00 Page 581
Collator area
3
1 2
LH
1 2 3
Remove the set screw (1). Remove the pulse disc. Remove the sensor (3).
Note Ensure on replacement that the pulse disc sensor clears both sides of the pulse disc.
Page 582
Collating area photocells
2 3
4 5 6 7
RH
LH
Transmitter (LED) 1 Move the lower collator arm downwards. 2 Remove the locking plate of the axle (4) at the right-hand side of the machine. 3 Free the bearings of the frame. 4 Remove the hinged guide plate (1) together with the attached sensors (2 and 3). Take care of the wiring. 5 Remove the transmitter (3) from the guide plate. Receiver (Sensor) 1 Follow step 1 to 4 of the above procedure. 2 Remove the sensor (2) from the guide plate.
Release: 07/2006
0 51.0067.1001.00 Page 583
Folder Folder input photocell Transmitter (LED) 1 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. 2 Cut the wire straps. 3 Remove the transmitter (6) from the bracket. Receiver (Sensor) 1 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. 2 Cut the wire straps. 3 Remove the receiver (7) from the bracket. Curve (pulse) disc sensor
LH
The sensors are located at the left-hand side of the upper unit. To remove the sensor: 1 Open the upper unit. 2 Remove the bracket (1) with the sensor (2). 3 Cut the wire strap. 4 Disconnect the sensor. 5 Remove the sensor from the bracket. Note The sensor (3) has to be removed in the same way.
Page 584
Inserter Pulse disc sensor
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 Remove the pulse disc (4). 2 Disconnect the wiring of the sensor (2). 3 Remove the two screws (3). 4 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.
Release: 07/2006
0 51.0067.1001.00 Page 585
Envelope track photocell

1 2
RH
RH
LH LH
Transmitter (LED) 1 Remove the insert table. 2 Remove the bottom plate. 3 Pull the air hose connector (4) from the transmitter (3). 4 Slacken the screw of the transmitter. 5 Remove the transmitter (3). Receiver (Sensor) 1 Remove the insert table. 2 Remove the bottom plate. 3 Remove the bracket (2) together with the sensor (1). 4 Slacken the screw of the sensor. 5 Remove the sensor (1).
Page 586
Envelope flap detector

1 2
3 4 5
Transmitter (LED) 1 Remove the insert table. 2 Remove the bottom plate. 3 Remove the bracket (1) with the transmitter (2). Take care of the wiring. 4 Disassemble the transmitter from the bracket. Receiver (Sensor) 1 Remove the insert table. 2 Remove the bottom plate. 3 Pull the air hose connector (3) from the sensor (4). 4 Slacken the screw (6). 5 Remove the bracket (5) with the sensor (4). 6 Remove the sensor from the bracket.
Release: 07/2006
0 51.0067.1001.00 Page 587
Document insert photocells

1 2 3 4 5
RH
RH
LH
LH
Transmitter (LED) 1 Open the upper unit. 2 Remove the screw (1) to release the transmitter (2). Receiver (Sensor) 1 Remove the transport table. 2 Slacken the screw (5). 3 Remove the bracket (4) with the sensor (3). 4 Remove the sensor from the bracket. Take care of the wiring.
Page 588
Closer photocell
1 2
3 4
5 6
RH
LH
To remove the flag switch: 1 Remove the nuts (1 and 6). 2 Remove the frame (2) complete. Take care of the wiring. 3 Slacken the screw (3). 4 Remove the bracket (4) with the photocell (5).
Release: 07/2006
0 51.0067.1001.00 Page 589
Exit photocells
RH
LH
4
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).
Page 590
5.2.14 Adjustment
Main drive PJ-belt
10 mm (0.4 inch) 1 2
The maximum movement of the drive belt at the indicated position is 10 mm (0.4 inch). To adjust: 1 Slacken the two screws (1) securing the belt tensioner (2). 2 Shift the belt tensioner to adjust the correct belt movement. 3 Hold the belt tensioner in position and retighten the two screws. 4 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.
Release: 07/2006
0 51.0067.1001.00 Page 591
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 Slacken the two screws (1) securing the belt tensioner (2). 2 Shift the belt tensioner to adjust the correct belt movement. 3 Hold the belt tensioner in position and retighten the two screws. 4 Check the adjustment and readjust if necessary.
Note Do not adjust the drive belt too tight.
Page 592
Main drive belt inserter
1 2
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 Slacken the two screws (1) securing the belt tensioner (2). 2 Shift the belt tensioner to adjust the correct belt movement. 3 Hold the belt tensioner in position and retighten the two screws. 4 Check the adjustment and readjust if necessary. Note Do not adjust the drive belt too tight.
Release: 07/2006
0 51.0067.1001.00 Page 593
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 Slacken the hexagonal head screw (3) securing the belt tensioner (2). 2 Shift the belt tensioner to adjust the correct belt movement. 3 Hold the belt tensioner and retighten the hexagonal head screw. 4 Check the adjustment and readjust if necessary. Note Do not adjust the drive belt too tight.
Page 594
Drive belt upper folder section
5 mm (0.2 inch)
The maximum movement of the drive belts 1 at the indicated position is 5 mm (0.2 inch). To adjust: 1 Slacken the hexagonal head screw (1) securing the belt tensioner (2). 2 Shift the belt tensioner to adjust the correct belt movement. 3 Hold the belt tensioner and retighten the hex. head screw. 4 Check the adjustment and readjust if necessary. Note Do not adjust the drive belt too tight.
Release: 07/2006
0 51.0067.1001.00 Page 595
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 Slacken the two round head screws (1) to move the guide plate (3) further away from the fold roller (2). 2 Tighten it to move it closer.
Page 596
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 Slacken the two screws (3) securing the solenoid coil (4). 2 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. 3 Hold the plunger in this position and then slide the solenoid coil towards the plunger until the plunger bottoms the solenoid coil. 4 Move the solenoid coil back by approximately 1 mm (0.04 inch). 5 Retighten the two screws. Ensure the solenoid coil and the plunger are aligned in a straight line.
Release: 07/2006
0 51.0067.1001.00 Page 597
Finger solenoid
RH
1 2 3 4
To adjust the finger solenoid: 1 Slacken the two screws (2) securing the solenoid coil (1). 2 Push the plunger (3) down into the lowest position. 3 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. 4 Retighten the two screws.
Page 598
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.
LH
RH
Should this occur, carry out the following adjustment: 1 Use the adjusting nut (2) and set the separation gap to the maximum. 2 Slacken the set screws (1) securing the separation roller. 3 Rotate the separation roller about 30 degrees in the direction indicated, so that the unworn portion of the separation roller faces the feed roller (3). 4 Retighten the set screw and re-adjust the separation gap. Note After rotating the separation roller over 330 degrees it is necessary to replace it.
Release: 07/2006
0 51.0067.1001.00 Page 599
Friction brake
2 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 Remove the outer nut (1) securing the inner nut (2). 2 Turn the inner nut to adjust the correct distance. 3 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.
Page 5100
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 Slacken the two hexagonal head screws (2) securing the flap scraper (3) on both sides. 2 Move the flap scraper to adjust the correct position. 3 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.
Release: 07/2006
0 51.0067.1001.00 Page 5101
5.3
Electrical description
An overview of all PCBs:
Board number 1 2 3 4 99.45.02 99.45.08 97.55.40 (110 V) or 97.55.00 (220 V) 99.20.03 (regular) or 99.20.01 (expanded) (optional) 99.20.02 (optional) 99.20.00 (optional) 99.45.00 99.45.04
Board name Display board Keyboard Motor relay board Connection board Modem board Communication board Main board ID Tag
5 6 7
Page 5102
5.3.1
Display board (FPi 4030 only)
Wiring display board
LC display touchscreen LC display CCFL
99.45.44
LC display data
Connector number J100 J101 J103 J104 J210
Release: 07/2006
0 51.0067.1001.00 Page 5103
98.90.82
Cable number 98.90.82 LC display CCFL LC display touch-screen LC display data 99.45.44
5.3.2
Keyboard
Wiring keyboard
99.45.44
Connector number J100
Cable number 99.45.44
Page 5104
5.3.3
Motor relay board
Wiring motor relay board

99.45.26 99.45.26 99.45.26
main motor
99.45.26
99.45.26
Connector number J1 J2
99.45.26
not in use
Cable number(s) 99.45.26 Main motor 110 V: 98.94.07 220 V: 98.94.06
J3 51 52 54 55 124
not in use 99.45.26 99.45.26 99.45.26 99.45.26 99.45.26
Release: 07/2006
0 51.0067.1001.00 Page 5105
5.3.4
a. Connection board, regular
Connection board
Wiring connection board (regular)
Page 5106
99.45.32
b. Connection board, expanded (optional)
Wiring connection board (expanded)
99.45.32
not in use 99.45.32
Connector number J105 J108
Cable number 99.45.32 99.45.32
Modem board The modem board is attached to the expanded connection board.
Release: 07/2006
0 51.0067.1001.00 Page 5107
5.3.5
Communication board (optional)
Page 5108
Wiring communication board

99.45.32 99.45.34 99.45.32 99.45.48 not in use
99.45.34
not in use
Connector number J101 J401 J402 J403 J502 J503
Cable number 99.45.34 99.45.32 99.45.48 99.45.32 99.45.34 not used
Release: 07/2006
0 51.0067.1001.00 Page 5109
Test points and LEDs on the communication board
TP102 D201 D202 D203 D204 D205 D206
TP101 D302
TP207
TP208 TP202 TP206 TP207 TP105
TP203 TP201
TP106
Page 5110
Test point TP101 TP102 TP105 TP106 TP201 TP202 TP203 TP205 TP206 TP207 TP208
Name GND GND +24V GND SDO SDI SCLK PB 5 PB 6 PB 7 PFO/CAL
Typical value 0 volt 0 volt 24 volt 0 volt
Function Debug ground Debug ground Supply check Electrical ground Debug only Debug only Debug only Debug only Debug only Debug only Debug only
LED D201 D202 D203 D204 D205 D206 D302
Color Green Green Green Green Green Green Red
Name TestLED 0 TestLED 1 TestLED 2 TestLED 3 TestLED 4 TestLED 5 Flsh wrt
Function No error heartbeat Modem activity Inserter communication activity (USB link) Franking interface (FIF) communication activity Service communication activity Debug LED Flash write in progress indication
Release: 07/2006
0 51.0067.1001.00 Page 5111
5.3.6
Main board
Page 5112
Wiring main board

98.90.18 98.90.28 98.90.24 99.45.26
98.90.32 98.90.32 98.90.32
99.45.32
99.45.34 99.45.32 99.45.48
99.45.30
98.94.08
98.90.30 98.90.36
99.45.20 98.90.20 98.90.22 98.90.10 98.90.82 98.90.30 99.45.24 99.45.22 99.45.36
98.90.34
Release: 07/2006
0 51.0067.1001.00 Page 5113
Connector number
Cable number
J100 J101 J102 J500 J501 J502 J600 J601 J602 J650 J700 J701 J800 J801 J802 J901 J902 J903 J1000 J1100
98.90.30 98.90.36 99.45.26 99.45.20 98.90.20 98.90.22 98.90.30 99.45.24 99.45.22 99.45.36 98.90.10 98.90.18 98.90.28 98.90.24 99.45.30 98.90.32 98.90.32 98.90.32 98.94.08 (Reading head) 99.45.32 (Without communication board) 99.45.34 (With communication board)
J1102
99.45.32 (Without communication board) 99.45.48 (With communication board)
J1120 J1200 (FPi 4030 only)
99.45.34 98.90.82
Page 5114
Test points and LEDs on the main board
TP103 TP105 TP901 TP900 TP903 TP902 TP904 TP906 TP800 D301 TP102
TP100 TP101
TP301 TP300 D301 D300 D702 D701 TP205
D303 TP202 TP204 TP203
TP201 TP1001 TP505 TP700 D500 TP600 TP500 TP502 TP501 TP503 TP200 TP1000
TP701
Release: 07/2006
0 51.0067.1001.00 Page 5115
Test point
TP100 TP101 TP102 TP103 TP105 TP200 TP201 TP202 TP203 TP204 TP205 TP300 TP301 TP500 TP501 TP502 TP503 TP505 TP600 TP700 TP701 TP800 TP900 TP901 TP902 TP903 TP904 TP906 TP1000
Name
+5V -12V +12V GND +24V Window DBG1 DBG2 DBG3 DBG4 DBG5 TST1 TST2 ENV FLAP LOC EXIT PDSC CLOSER COLL FO PD COL FE-1 FE-3 DFC FE1 DFC FE3 FE-2 DFC FE2 OMR OUT
Typical value
5 volt -12 volt 12 volt 0 volt 24 volt 5 volt X X X X X X X 1.2 volt 1.2 volt 1.2 volt 1.2 volt 5 volt or 0 volt 1.2 volt 1.2 volt 1.2 volt 5 volt or 0 volt 1.2 volt 1.2 volt Depends on paper thickness Depends on paper thickness 1.2 volt Depends on the paper thickness Depends on the paper reflection and marks
Function
Supply check Supply check Supply check Electrical ground Supply check OMR window oscilloscope trigger Debug only Debug only Debug only Debug only Debug only Debug only Debug only Envelope photocell Flap photocell Loc photocell Exit Main pulsedisc signal Closer photocell Collator photocell Folder photocell Collator pulsedisc Feeder 1 photocell Feeder 3 photocell DFC out feeder 1 DFC out feeder 3 Feeder 2 photocell DFC out feeder 2 Analog OMR signal
Page 5116
Test point
TP1001
Name
ReadHead
Typical value
1.2 volt
Function
Readhead photocell
LED D300 D500 D701 D702 D801 D301 D303
Color Green Green Green Green Green Red Red
Name TST1 PDSC FT1 FT2 PD COLL TST2 Flash write
Function No error heartbeat Main pulsedisc indication Folding table 1 indication Folding table 2 indication Collator pulsedisc indication Error heart beat Flash write in progress indication
Flex OMR (FPi 4030 only) 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 FPi 4030 or FPi 2000-2.
number 37
DS1977
Release: 07/2006
0 51.0067.1001.00 Page 5117
5.3.7
ID-tag (99.45.04)
Wiring ID-Tag
Page 5118
99.45.36
5.4
Maintenance
Note The maintenance schedule has been published in the Technical Bulletin FP47-4030
Release: 07/2006
0 51.0067.1001.00 Page 5119
Page 5120
SERVICE MANUAL FPi 4030 INSERTING SYSTEM Fault finding
Fault finding
6.1 Remotely resolving problems
For remotely diagnosing customer problems, check the following with the customer: The machine type and serial number (Look on the sticker [on the internal frame]): 1 Open the front cover 2 Read the machine type and serial number The customer's failure description. 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 Incase 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. Please note Error messages can be looked up online in the Service Knowledge Database (SKD).
Release: 07/2006
0 51.0067.1001.00 Page 61
6.2
Error handling
All error screens have the following in common:
Info. Additional information if the info key 1 is pressed. See picture below.
A message. The message that is displayed next to the exclamation mark triangle.
An action. The text that is displayed next to the finger pictogram.
Additional information, cause and remedy.
An error code of the pattern X:YYY, where X is an abbreviation that indicates a specific machine part. YYY is a digit between 0 and 999, indicating the specific error.
The following machine areas/prefixes apply: - INS = Inserter - FO = Folder - VT = Collator, vertical transport and OMR - FE1, FE2, FE3 = Feeder 1 to 3 - CB = Communication board - INF = Insertn FrankTM
Page 62
6.3
Error Codes
Please note The following pages contain a printed version. The current Error Codes can be looked up online in the Service Knowledge Database (SKD).
Release: 07/2006
0 51.0067.1001.00 Page 63
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
Inserter errors (INS) INS:1 Technical failure INS:2 INS:3 Technical failure Technical failure
FRAM chip is not available FRAM chip is not formatted FRAM chip contains old data structure FRAM chip contains corrupt dat Communications failure Communications failure
INS:4a-z Technical failure INS:5 INS:6 INS:10 Technical failure Technical failure Envelope too long
System error. This error is generated during starting up or operation of the machine. System error. This error is generated if the machine is started up (at least) the first time. System error. This error is generated during starting up of the machine. System error. This error is generated during reading of a data block.
X X X X X X X
INS:11
Document inserting failure
INS:12
Document length failure
INS:13 INS:14
Envelope stoppage at exit Document too thin
INS:15
Envelope not open
Envelope separation adjustment, envelope This error is generated if a closed envelope is type, envelope quality, envelope job measured higher than 182 mm (162 mm + 20 mm settings, photocells dusty tolerance) or if the envelope is measured higher than the adjusted envelope height plus 20 mm. Insert fingers, envelope stop position, This error is generated if the insert cell is covered envelope job settings, document skewing, too long during inserting. Too long means longer document, slippage, document feeding, than 400 mm (800 flanks). envelop feeding Insert fingers, envelope stop position, This error is generated if on two inserts directly after document job settings, document skewing, each other a length difference is measured of more document slippage, document feeding than 42 mm (84 flanks). This means irregular inserting (slip on insert rollers?). Blockage at envelope exit, inserting failure, This error is generated if the exit detector is covered skewing, slippage, exit blockage longer than 300 ms. Envelope separation adjustment, envelope This error is generated if the envelope flap is not type, envelope job settings, photocells opened. dusty, slippage Envelope exit path, slippage, envelope This error is generated if the envelope does not type, inserting failure, flap closer sensor arrive within 400 mm (800 flanks) at the exit cell, after detecting the envelope by the closer switch.
X X X
X X X
State: based on rev. 01.0 - 03/2006

Error_handling_EN_FPi4030_2000-2_20060710a.doc
Page 1 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
INS:16
Envelope stoppage
INS:17 INS:18 INS:19
Unexpected document Unexpected document Envelope stoppage
INS:21 INS:22
Thickness not measured Envelope too short
Envelope separation adjustment, envelope This error is generated if a closed envelope is type, envelope quality, envelope job measured higher than 182 mm (162 mm + 20 mm settings, photocells dusty tolerance) or if the envelope is measured higher than the adjusted envelope height plus 20 mm. Document path not correctly cleared after This error is generated if a document arrives at the previous error, slippage, inserting failures insert area at a not expected moment. Document path not correctly cleared after This error is generated if the insert cell is covered at previous error, slippage, inserting failures the moment a document is called. Blocked envelope path, envelope This error is generated if the flap sensor is covered separation adjustment, envelope type, more than 690 flanks (approx. 345 mm). envelope job settings, dusty photocells, slippage Incorrect measurement area for DFC 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. Envelope path not cleared after previous This error is generated if the closer cell is covered at jam, envelope closing sensor readjustment the moment an envelope/document should leave the needed, dirty sealing track, insert failures insert area. Envelope closing path not cleared after This error is generated if the flap closer sensor is previous jam, slippage, dirty sealing track, covered too long. Longer than the time that meets a insert failures, skewing document transport of 550 flanks (approx. 275 mm). 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). Blocked document path, slippage This error is generated if the called document does not arrive at the insert cell. Blocked document or envelope path after This error is generated if a document covers the previous stoppage insert cell at the moment the system is started. Incorrect envelope type, envelope job settings, photocell readjustment needed
X X X
X X X
X X X
INS:23
Envelope closer failure Envelope closure failure Envelope stoppage
X X X
X X X
INS:24
INS:26
INS:27 INS:29
Document stoppage Insert area blocked
X X

Page 2 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
INS:30
Empty envelope hopper
Empty hopper, wrong envelope type, envelope width setting, envelope separation adjustment, envelope feeding angle Total counter equal to Service Counter, Service counter incorrect SCS protocol problem Main motor defect, pulse disc defect, cables defect
This error is generated if it takes longer than 15 seconds to detect an envelope at the env.tracksensor after the envelope track was started.
INS:34 INS:35
Technical failure Preventive maintenance needed Technical failure Technical failure This error is generated if the next visit service counter value is reached. The message will appear at system start. Check cables, connectors, PCB or software versions. System error. This error is generated if the pulse disk of the main power does not generate enough pulses or if the broadness 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. This error is generated if the DFC is not detected. 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. Refer to INS:44 Refer to INS:44 Refer to INS:44
X X X X
X X
INS:36 INS:37
INS:38 INS:44
Technical failure Technical failure
DFC not connected, DFC defect Envelope track sensor adjust error. Led current cannot be adjusted to have photocell voltage between 0.8 and 1.3 V. Dusty, incorrect positioning, incorrectly assembled.
X X
Technical failure Technical failure Technical failure
Envelope flap sensor adjust error Insert sensor adjust error Exit sensor adjust error
X X X

Page 3 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
INS:48
Envelope track sensor error
Too much voltage received by photocell. Current cannot be correctly adjusted (too low)
INS:49 INS:50 INS:51 INS:52
Envelope flap sensor error Insert sensor error Exit sensor error Technical failure
Refer to INS:48 Refer to INS:48 Refer to INS:48 LED current adjusted too low. Envelope track sensor adjust error
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. Refer to INS:48 Refer to INS:48 Refer to INS:48 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. Refer to INS:52 Refer to INS:52 Refer to INS:52
X X X X
Technical failure Technical failure Technical failure
Envelope flap sensor adjust error. Refer to INS:52. Insert sensor adjust error. Refer to INS:52. Exit sensor adjust error. Refer to INS:52.
X X X

Page 4 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
INS:56
Technical failure
Envelope track sensor defective. Photocell, cables or connectors defect.
INS:57 INS:58 INS:59 INS:60
Technical failure Technical failure Technical failure Envelope track sensor error
Envelope flap sensor defective. Refer to INS:56. Insert sensor defective. Refer to INS:56. Exit sensor defective. Refer to INS:56. Voltage received by the photocell is too high due to dust fall off
Power up photocell detection error. 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. Refer to INS:56 Refer to INS:56 Refer to INS:56 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. Refer to INS:60 Refer to INS:60 Refer to INS:60
X X X X
Envelope flap sensor error Insert sensor error Exit sensor error
Refer to INS:60 Refer to INS:60 Refer to INS:60
X X X

Page 5 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
INS:64
Envelope track sensor dusty
Low voltage received by the photocell (dusty)
INS:65 INS:66 INS:67 INS:68 INS:69 INS:70 INS:71 INS:72 INS:73 INS:80 INS:81 INS:82 INS:83 INS:84 INS:85
Envelope flap sensor dusty Insert sensor dusty Exit sensor dusty Closer sensor error Technical failure Technical failure Closer sensor error Closer sensor dusty Technical failure Technical failure Technical failure Technical failure Technical failure Technical failure Technical failure
Refer to INS:64 Refer to INS:64 Refer to INS:64 Refer to INS:48 Closer sensor adjust error. Refer to INS:52 Closer sensor defective. Refer to INS:56 Refer to INS:60 Refer to INS:64 Closer sensor adjust error. Refer to INS:44 SCS/I2C protocol problem, cables, connectors, pcbs SCS/I2C protocol problem, cables, connectors, pcbs SCS/I2C protocol problem, cables, connectors, pcbs SCS/I2C protocol problem, cables, connectors, pcbs SCS/I2C protocol problem, cables, connectors, pcbs SCS/I2C protocol problem, cables, connectors, pcbs
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: The involved photocell values are reset. Go back to the main menu. Refer to INS:64 Refer to INS:64 Refer to INS:64 Refer to INS:48 Refer to INS:52 Refer to INS:56 Refer to INS:60 Refer to INS:64 Refer to INS:44 System error. This error is generated if something is wrong with the SCS/ I2C. System error. This error is generated if something is wrong with the SCS/ I2C. System error. This error is generated if something is wrong with the SCS/ I2C. System error. This error is generated if something is wrong with the SCS/ I2C. System error. This error is generated if something is wrong with the SCS/ I2C. System error. This error is generated if something is wrong with the SCS/ I2C.
X X X X X X X X X X X X X X X

Page 6 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
INS:86 INS:87 INS:88 INS:89 INS:95 INS:101 104 INS:105 INS:106 INS:109 INS:180
Technical failure Technical failure Technical failure Technical failure Sealing risk Cover open Communication failure Illegal configuration Envelope stoppage
SCS/I2C protocol problem, cables, connectors, pcbs SCS/I2C protocol problem, cables, connectors, pcbs SCS/I2C protocol problem, cables, connectors, pcbs SCS/I2C protocol problem, cables, connectors, pcbs Sealing risk Cover open, cover switches defect or loose, envelope track sensors SCS protocol problem, cables, connectors, pcbs Incorrect software installed Envelope lost in envelope track
System error. This error is generated if something is wrong with the SCS/ I2C. System error. This error is generated if something is wrong with the SCS/ I2C. System error. This error is generated if something is wrong with the SCS/ I2C. System error. This error is generated if something is wrong with the SCS/ I2C. This error is generated if during a run a cover is opened. This error is generated if there is a SCS protocol problem. This error is generated if the Inserter software does not match with the feeder/folder software. This error is generated when the envelope goes under the flap opener. 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. 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. 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.
X X X X X X
X X X
X X
Update options failed ID/Option memory defect
INS:181
Option memory failure
Option memory defect or general hardware defect
INS:182
Option memory failure
ID memory empty, wiring defect, ID/Option memory defect

Page 7 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
INS:183
Invalid data in option memory/ ID tag
INS:184
Serial number already present in 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. Machine's software and identity are setup already
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.
INS:185
Invalid license key entered
Invalid licence key, or licence key for other machine
INS:186
Illegal configuration
Illegal configuration detected
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. This error is generated if the entered 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. This error is generated when the serial number in the ID-tag (99.45.04) 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 (99.45.04) do not match. See Section 4.3.8 Remove blockage. This error is generated when paper is left in the folder after a job change. 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. This error is generated if 500 ms after powering the clutch of the 1td 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.
Folder errors (FO) FO:7 Document stoppage FO:8 Folder entry blockage
Set not removed after job change Document feeding, document separation, document path not cleared after previous stoppage, skewing of set, slippage Document set thickness, mechanical defect in first fold table, folding sensors defect
X X
FO:11
Folding failure

Page 8 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
FO:12
Folding failure
Document set thickness, mechanical defect in first fold table, folding sensors defect
FO:14
not possible
Not supported documents and envelope type detected for Fill&Start
FO:61
Technical failure
Led current cannot be adjusted to have photocell voltage between 0.8 and 1.3 V. Dusty, incorrect positioning, incorrectly assembled
FO:62
Folder entry sensor error
This error is generated if 500 ms after powering the clutch of the 2ntd fold table no flank is detected on the curve disc sensor of the 2nd fold table. Possible causes: fold table blocking by a not foldable document (stiff material), mechanical defect on fold table, clutch or sensor. 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. 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. 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.

Page 9 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
FO:63
Technical failure
LED current adjusted too low
FO:64
Technical failure
Photocell, cables or connectors defect
FO:65
Folder entry sensor error
Voltage received by the photocell is too high due to dust fall off
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. Power up photocell detection error. 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. 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.

Page 10 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
FO:66
Folder entry sensor 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.
Collator, vertical transport and OMR errors (VT) VT:9 Collator stop error Incorrect collator stop position, mechanical This error is generated if it takes too long before a failure set arrives at the folder entry sensor. Is only checked at job start. VT:10 Document transport Document path blockage, slippage, This error is generated if the document does not failure vertical track photocells dusty arrive in time at the collator entry cell (if transport time between leaving feeder and arriving at folder entry exceeds 700 mm (750 pulses). VT:11 Document transport Document type, document path blockage, This error is generated if the collator entry cell is failure photocells dusty, photocells defect covered too long. Possible causes: too stiff material, collator blocked. VT:12 Document transport Document set missing from collator, This error is generated if no documents arrive at the failure photocells readjustments needed, folder entry cell. Possible causes: paper crash or the photocells defect operator pressed STOP, removed the set from the collator and pressed <START>. VT:14 Unexpected Collator not cleared after previous During initialisation of the collator a set (part) is seen document at collator emergency stop under the folder entry cell. The collator is initialised after fatal feeder errors, after collator errors and after a change of job. VT:16 Collator stop Zero position sensor failure, rack broke or During initialisation of paper stop detection the reference detection collator stop motor failure sensor for detecting zero position could not detect failed the zero position. Cause: zero position sensor failure, rack broke or collator stop motor failure.
X X
X X X

Page 11 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
VT:17
Collator stop detection failed
Stop position sensor failure, rack broke or collator stop motor failure
VT:20
Unexpected documents in system
System not cleared after job change
VT:21
Empty feeders
VT:61
Technical failure
Empty feeders, wrong document type, document width setting, manual document separation adjustment Led current cannot be adjusted to have photocell voltage between 0.8 and 1.3 V. Dusty, incorrect positioning, incorrectly assembled
During initialisation of paper stop detection the sensor for detecting paper stop position could not detect the zero position. Cause: stop position sensor failure, rack broke or collator stop motor failure. This error is generated if documents are still in the system after a change of jobs. This can be prevented by ending a job with emptying the system, before changing jobs. This error is generated if all feeders are empty during the Fill&Start scanning session. 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. 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.
X X
VT:62
Vertical track sensor error

Page 12 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
VT:63
Technical failure
VT:64
Technical failure
VT:65
Vertical track sensor error

Page 13 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
VT:66
Vertical track sensor dusty
VT:70
Technical failure
Blockage of collator, collator pulse disc defect, collator motor defect
VT:71 VT:72 VT:73 VT:74 VT:75 VT:76 VT:101
Technical failure Collator entry sensor error Technical failure Technical failure Collator entry sensor error Collator entry sensor dusty Technical failure
Refer to VT:61 Refer to VT:62 Refer to VT:63 Refer to VT:64 Refer to VT:65 Refer to VT:66 Incorrect dongle installed, dongle contents cannot be read
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. This error is generated if the DC motor of the collator is not running while it is supposed to. The error is shown when there are no pulses detected for 100 msec. 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. Refer to VT:61 Refer to VT:62 Refer to VT:63 Refer to VT:64 Refer to VT:65 Refer to VT:66 OMR error. This error is generated if the dongle checksum is incorrect or if the serial number check is incorrect. This error is not generated when a valid OMR dongle is removed or when an invalid dongle is placed. OMR error. This error is generated if the LED in the reading head is defect.
X X X X X X X
VT:102
Technical failure
Reading head dirty, LED defect, photocell defect, cables defect

Page 14 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
VT:112 VT:113
Wrong reading window position Reading stop
Incorrect RD job settings Stop mark read
VT:114
Suspected set
Incomplete sets collected after reading error
VT:116
Reading stop
Divert mark read
VT:120
Reading error
Less marks read than expected
VT:121
Reading error
More than 1 basic command (accumulate/ insert/ divert/ stop mark) read
VT:122
Reading error
No basic command (accumulate/ insert/ divert/ stop/ start/ safety mark) read
OMR error. This error is generated when the reading window is behind the end of the paper. OMR error. Remove the set and press <reset>. A complete set is on the collator and must be handled manually. This error is not generated in the FPi 2000-2. OMR error. This error is generated after an earlier appeared reading error. The paper run commend "insert" is read. The earlier appeared reading error probably occurred halfway a set, because of which that set and the next one are incomplete. OMR error. Remove the set and press <reset>. A complete set is on the collator and must be handled manually. This error is not generated in the FPi 2000-2. OMR error. This error is generated if less reading code stripes 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 VT:114 shows. OMR error. This error is generated if more paper running assignments are 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 VT:114 shows. This error does not show for the FPi 2000-2. 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 VT:114 shows.
X X

Page 15 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
VT:123
Reading error
Matching varies within the set
VT:124
Reading error
Sequence number of document does not match with previous document
VT:125
Reading error
Matching number of set is not correct (related to previous set)
VT:126
Reading error
Parity of the marks read is not correct. Reading window incorrect? RD marks incorrect. Check RD settings.
VT:127
Reading error
A mark is read at an illegal position
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 VT:114 shows. This error does not show for the FPi 2000-2. 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 VT:114 shows. This error does not show for the FPi 2000-2. 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 VT:114 shows. This error does not show for the FPi 2000-2. OMR error. This error is generated if the parity of a read barcode 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 VT:114 shows. 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 VT:114 shows.

Page 16 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
VT:128
Reading error
Incorrect marks read, RD job settings, slippage, reading head adjustments needed
VT:129
Reading error
Incorrect marks read, RD job settings, reading window too long
VT:134
Too many documents
Set size exceeds maximum number from RD job settings, incorrect marks read
VT:135
Final set part
Incorrect marks read, RD job settings
VT:137
Reading error
No safety mark read
OMR error. This error is generated if the position of a barcode line is moved that far, that it is 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 VT:114 shows. OMR error. This error is generated if more barcode lines are present than 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 VT:114 shows. OMR error. Remove the set and press <RESET>. To subsequently 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. 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 VT:134. If, subsequently, again the maximum amount of sheets in a set is exceeded, error VT:134 is generated again. 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 VT:134 Suspected set.

Page 17 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
VT:138
Reading error
Group start mark error
VT:139
Reading error
Group end 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 VT:134 Suspected set. 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 VT:134 Suspected set. 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. This error is generated if a feeder inserts a double page. This is a fatal error. This error is generated if the sheet on which the DFC is adjusted was a double sheet. This error can only be generated with the first sheet that a feeder hands in after adjustment (when this sheet is thinner than the one that was used for the adjustment). This is a fatal error. This error is generated if a feeder hands in 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. This error is generated if a feeder is handing in 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. This error is generated if a feeder hands in 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.
Feeder errors (FE) FE1:0 Empty feeder
Empty feeders, wrong document type, document width setting, manual document separation adjustment
FE1:10
Document too thick
FE1:11
Feeding failure
Document type, document separation adjustment (manual separation only), separation rollers worn out Incorrect thickness reference, irregular document types, DFC defect or loose
X X X
FE1:12
Document too long
Document separation adjustment (manual separation only, document type, document job settings, photocells dusty Blocked document path, document separation adjustment (manual separation only), document type, document job settings, photocells dusty Incorrect document type, document job settings, photocell readjustment needed
FE1:13
Document stoppage
FE1:14
Document too short

Page 18 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04
TM
05
06
07
FE1:20
MaxiFeederTM failure
Incorrect job settings for MaxiFeeder
FE1:21
Unauthorized job
Incorrect document job settings, dongle reading failure
FE1:22 FE1:51
MaxiFeederTM failure Technical failure
Refer to FE1:20 Led current cannot be adjusted to have photocell voltage between 0.8 and 1.3 V. Dusty, incorrect positioning, incorrectly assembled
FE1:52
Feeder sensor error
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 doc length is adjusted to >156 mm and/or to multifeed. 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 doc length for that half station is adjusted to >156 mm and/or to multifeed. Refer to FE1:20 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. 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.
X X

Page 19 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
FE1:53
Technical failure
FE1:54
Technical failure
FE1:55
Feeder sensor error

Page 20 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
FE1:56
Feeder sensor dusty
FE1:60
Feeding failure
Document separation failing, DFC defect, Cables defect
FE1:61 FE1:62
DFC failure Technical failure
DFC defect, cables defect DFC defect, cables defect
FE2:0
Empty feeder
FE2:10
Document too thick
Document type, document separation adjustment (manual separation only), separation rollers worn out
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. This error is generated when the DFC 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 FE1 t/m FE3):61 shows. There is a defect in the DFC. This error is generated if the DFC can not be adjusted. 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. 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. This error is generated if a feeder inserts a double page. This is a fatal error.
X X X

Page 21 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
FE2:11
Feeding failure
Incorrect thickness reference, irregular document types, DFC defect or loose
FE2:12
Document too long
FE2:13
Document stoppage
FE2:14
Document too short
FE2:20
Incorrect job settings for MaxiFeederTM
FE2:21
Unauthorized job
FE2:22
Refer to FE1:20
This error is generated if the sheet on which the DFC is adjusted was a double sheet. This error can only be generated with the first sheet that a feeder hands in after adjustment (when this sheet is thinner than the one that was used for the adjustment). This is a fatal error. This error is generated if a feeder hands in 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. This error is generated if a feeder is handing in 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. This error is generated if a feeder hands in 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. 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 doc length is adjusted to >156 mm and/or to multifeed. 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 doc length for that half station is adjusted to >156 mm and/or to multifeed. Refer to FE1:22

Page 22 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
FE2:52
Feeder sensor error
FE2:53
Technical failure
FE2:54
Technical failure
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. 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. Power up photocell detection error. 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.

Page 23 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
FE2:55
Feeder sensor error
FE2:56
Feeder sensor dusty
FE2:60
Feeding failure
Document separation failing, DFC defect, Cables defect
FE2:61 FE2:62
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. 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. This error is generated when the DFC 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 FE1 t/m FE3):61 shows. There is a defect in the DFC. This error is generated if the DFC can not be adjusted. 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.
X X

Page 24 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
FE3:0
Empty feeder
FE3:10
Document too thick
FE3:11
Feeding failure
Document type, document separation adjustment (manual separation only), separation rollers worn out Incorrect thickness reference, irregular document types, DFC defect or loose
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. This error is generated if a feeder inserts a double page. This is a fatal error. This error is generated if the sheet on which the DFC is adjusted was a double sheet. This error can only be generated with the first sheet that a feeder hands in after adjustment (when this sheet is thinner than the one that was used for the adjustment). This is a fatal error. This error is generated if a feeder hands in 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. This error is generated if a feeder is handing in 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. This error is generated if a feeder hands in 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. 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 doc length is adjusted to >156 mm and/or to multifeed.
X X
X X
FE3:12
Document too long
FE3:13
Document stoppage
FE3:14
Document too short
FE3:20
Incorrect job settings for MaxiFeederTM

Page 25 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
FE3:21
Unauthorized job
FE3:22 FE3:51
MaxiFeederTM failure Technical failure
Refer to FE1:20 Led current cannot be adjusted to have photocell voltage between 0.8 and 1.3 V. Dusty, incorrect positioning, incorrectly assembled
FE3:52
Feeder sensor error
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 doc length for that half station is adjusted to >156 mm and/or to multifeed. Refer to FE1:22 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. 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.
X X

Page 26 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
FE3:53
Technical failure
FE3:54
Technical failure
FE3:55
Feeder sensor error

Page 27 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
FE3:56
Feeder sensor dusty
FE3:60
Feeding failure
Document separation failing, DFC defect, cables defect
FE3:61 FE3:62
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. This error is generated when the DFC 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 FE1 t/m FE3):61 shows. There is a defect in the DFC. This error is generated if the DFC can not be adjusted. 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. OLS message. At start up of system when OLS is enabled and new messages are available in OLS menu. 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: choice "Continue without action"or "Initialise communication board".
X X
Communication board errors (CB) CB:0 New online service New OLS message on communication messages board CB:1 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.

Page 28 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
CB:2
Technical failure
Communication board missing or defect, or internal cables or PCB defect
CB:4
Technical failure
CB:5
Technical failure
No modem available/ detected, modem defect, modem not plugged in, cable defect, no connector board, connector board defect The installed modem could not be detected as a legal version Internal cables defect or Communication/ Connection board defect
OLS or INF error. At IN startup and configuration check. Also when INF info is needed (INF job start, INF job adjust). Communication board is expected because of service settings or licence. Cause: internal Cables, PCB defect. OLS error. At IN startup and configuration check and modem is expected because of service settings or licence. OLS error. At IN startup and configuration check and modem is expected because of service settings or licence. 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. OLS error. At IN startup and configuration check (only when OLS is switched on in service menu). During run, system should continue. OLS error. At IN startup and configuration check (only if OLS is switched on in service menu). 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. During start up, and OLS/FIF is enabled. During start up, and OLS/FIF is enabled. During start up, and OLS/FIF is enabled. When reading data block. At IN startup and configuration check. Communication board is expected because of service settings or licence. Page 29 of 38
CB:6
Technical failure
CB:7 CB:8 CB:9 CB:10
Technical failure Technical failure Technical failure Auto connection failure
Modem not ready or serial port initialisation of modem failed Clock update received from server failed Communication board has had power dip Automatic connection failed. Statistic buffer overflow >95%, batch data might be lost FRAM chip not available on communication board FRAM not formatted FRAM contains old data structure FRAM contains corrupt data Incorrect software in communication board or inserter board
CB:11 CB:12 CB:13 CB:14a.. z CB:15
Technical failure Technical failure Technical failure Technical failure Technical failure

FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
CB:16 CB:17 CB:50
Technical failure Technical failure No analogue phone detected No dial tone
PCB communication board failure ISIS link down between main board and communication board There is no analogue phone line connected to the machine or the line is faulty The modem failed to detect a dial signal. Could also happen if the phone-line is not connected
During start up of the system (and OLS/FIF is enabled). Communication lost between inserter and communication board. OLS message: At Osiris connection set up Check the phone-line.
CB:51
CB:52 CB:54
OLS dialling interrupted by user OLS line busy
CB:57
OLS connection refused by server Protocol error
CB:58
CB:61 CB:62
CB:63 CB:64 CB:65
Automatic stats upload failed Configuration upload/download failed Automatic software download failed Automatic job download failed Automatic feature download failed
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). The user/supervisor pressed the OLS message: At the initiation of a new OLS disconnect button while dialing out connection and the drilling is interrupted by user. 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. At setting up an OLS connection the OLS message: The IP settings are not correct. authentication process of the system failed Check IP number and port. Also it could be that the because system is not allowed to connect device is not allowed to authenticating. The connection to the server succeeded OLS message: The device is not know by the server. but the server doesn't allow this device to Check on the OLS server if this device serial number communicate with the server is known by the server. The upload of statistics is interrupted Ask OLS server administrator to investigate. The upload of the configuration information Ask OLS server administrator to investigate. is interrupted A software download is interrupted A job download is interrupted A feature download is interrupted Ask OLS server administrator to investigate. Ask OLS server administrator to investigate. Ask OLS server administrator to investigate.

Page 30 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
CB:66 CB:67
Automatic flex code download failed No carrier
A flex OMR download is interrupted The modem failed to negotiate with the modem of the server
Ask OLS server administrator to investigate. OLS message: At the initiation of a new OLS connection. This could have 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.
Insertn FrankTM errors (INF) INF:00 Cover open on franking machine INF:1 Franking machine stopped via start/stop key
Cover opened during INF run 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. Due to a time out INF decided that communication with the FM has dropped. Caused by an internal problem at the FM or by disconnecting the serial cable. Check the cabling and restart the job from the IN. If this fails, switch off/on the FM or the whole system. This error is raised when an envelope is not franked within X seconds after having left the insert area (system and configuration dependent). The envelope might not be franked by the FM. Possible presence of envelopes in FM from previous job, or envelopes manually put onto the FM during the job, so more envelopes have been franked than was foreseen by the INF.
INF:2
No communication with franking machine
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 that can not be adjusted and knobs that belong with that fields are grey. Only "pass through" can be selected. During run.
INF:3
Envelope stoppage between inserter and franking machine
INF:4
More envelopes have been franked than sent by the inserter system
During run.

Page 31 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
INF:5
Internal error on franking machine
INF:6
Error or warning on franking machine
INF:7
Communication failure with franking machine Communication failure with franking machine Communication failure with franking machine Selecting franking machine job failed
INF:8
INF:9
INF:10
INF:11
An internal error occurred which blocks job execution
At the FM an error has 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. At the FM an error has 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. Due to some unsupported error (condition) the FM refuses to start. The user has to try to start the job from the IN again. If this fails the FM has to be switched on/ off. INF received incorrect envelope data (unknown hopper or invalid hopper data). Remove any envelopes from the system and try to start the job again. INF received incorrect envelope data (unknown thickness or invalid thickness data). Remove any envelopes from the system and try to start the job again. Unable to select a job at the FM due to an unsupported error (condition). Try to restart the job again or switch off/on the FM. Unable to make some settings at the FM due to an unsupported error (condition). Try to restart the job again or switch off/on the FM.
During run or pressing start key.
When pressing start key.
During run.

Page 32 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
INF:12
An internal error occurred which blocks job execution An internal error occurred which blocks job execution An internal error occurred which blocks job execution An internal error occurred which blocks job execution Franking machine is in stand alone mode
INF:13
INF:14
INF:15
INF:16
Unable to retrieve settings from the FM due to an unsupported error (condition). Try to restart the job again or switch off/on the FM. Unable to configure the 'Base' (FM) due to an unsupported error (condition). Try to restart the job again or switch off/on the FM. Unable to configure the 'Advanced Feeder' (AF) due to an unsupported error (condition). Try to restart the job again or switch off/on the FM. Due to some unsupported error (condition) INF is unable to stop the FM. Switch off/on the FM. The FM is being used 'stand alone'. As a result INF cannot gain control over the FM.
During run.
INF:17
Communication failure with franking machine Communication failure with franking machine
INF:18
INF:19
Franking machine already started
Due to some unsupported error (condition) the FM did not complete the starting sequence in time. Try to start the job again or switch off/on the FM. A time-out occurred when attempting to During run. wake up the 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. The FM cannot be started as it is already When pressing start key. 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.
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 that can not be adjusted and knobs that belong with that fields are grey. Only "pass through" can be selected. During run.

Page 33 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
INF:20
Internal error on franking machine
INF:21
Selecting franking machine job failed
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. 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.
INF:22
Communication failure with franking machine The franking machine is in error mode
INF:23
INF:24
The franking machine is in busy mode Internal failure on franking machine
INF:25
INF:26
Communication failure with franking machine Communication failure with franking machine
INF:27
Indicates that the FM won't accept commands and/or data from INF. Just wait and try to start the job again or switch off/on the FM. INF is not able to configure the FM as some error has occurred that has not yet been solved and is not specified. Please check the FM UI for any message and close any covers. Otherwise switch off/on the FM. INF is not able to configure the FM as the FM is busy for some unknown. reason Please wait a while, otherwise switch off/on the FM. Unable to configure the 'Dynamic Scale' (DS) due to an unsupported error (condition). Try to restart the job again or switch off/on the FM. The FM did not complete the stop sequence in time. The FM might have to be switched off/ on in order to continue with another job. During job execution the FM terminated the job unexpectedly for some unknown reason. Try to restart the job again or switch off/on the FM.
At changing DS+MS job settings (for which information from FM is needed) or starting DS+MS job. In job edit, after reset: continue the job edit menu. The fields that can not be adjusted and knobs that belong with that fields are grey. Only "pass through" can be selected. When pressing start key.

Page 34 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
INF:28
INF:29
Auto clean on franking machine in progress Cover open on franking machine
Notification from the FM that the Auto Clean Cycle will be started very soon. 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. Due to some fatal error condition communication with the FM has dropped in Alayer. Try to start the job again or switch off/ on the FM or the system as a whole. Due to some fatal error condition communication with the FM has dropped in Tlayer. Try to start the job again or switch off/ on the FM or the system as a whole. Due to some fatal error condition communication with the FM has dropped in Dlayer. Try to start the job again or switch off/ on the FM or the system as a whole. INF received an envelope 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. INF received data for the next envelope while the current envelope has not yet left the waiting position. Restart the job. The FM has popped up a dialog to enter the user PIN code. Job execution will be blocked until the correct PIN code has been entered.
INF:30
Communication failure with franking machine
INF:31
INF:32
INF:33
Communication failure
INF:34
Wait position occupied User PIN code required at franking machine
INF:35

Page 35 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
INF:36
Department PIN code required at franking machine
INF:37
INF:38
Wrong PIN code entered on franking machine Unknown envelope detected
INF:39
Unknown envelope detected
INF:40
Auto clean on franking machine is finished Auto clean on franking machine time out
INF:41
INF:42
An internal error occurred which blocks job execution
INF:43
The franking machine is in supervisor mode
The FM job selected requires 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. The user has entered the wrong PIN code and the FM will go into 'sleep' mode. Job execution is blocked. INF has detected a physical envelop at the wait position, but did not receive any data for it. The envelope (if any) has to be removed. INF has detected a physical envelop at the wait position, but was not notified about its arrival. The envelope (if any) has to be removed. Notification from INF that the Auto Clean Cycle has been completed and the franking process will be resumed automatically. Notification from INF that the Auto Clean Cycle takes more time than expected. Either the user wait until the FM has actually finished Auto Clean or the FM has to be switched off/ on. For some reason the FM is busy and won't accept commands from INF. Possibly the FM was manually started by the user. Otherwise the FM has to be switched off/ on. An attempt is made to execute a job while the FM is in Supervisor mode. Exit Supervisor mode at the FM and try to start the job again.

Page 36 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
INF:44
INF:45
INF:46
INF:47
INF:48
INF:49
Franking machine At the FM is currently a dialog being not ready for franking displayed as a result of an error (condition) interface that occurred while INF was not executing a job on the FM. Probably the FM was used stand alone. Inspect the FM UI and act upon it. An internal error Concerns incorrect set up of the option. occurred which The INF level is set to blocks job execution INF_LEVEL_NO_INF. Probably caused by incompatible software versions of Inserter and INF module. Internal error, not user solvable. An internal error Concerns incorrect set up of the option. An occurred which attempt was made to set the franking blocks job execution 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. An internal error INF is busy and cannot accept any occurred which commands. An attempt was made to blocks job execution change settings while INF is busy. Internal error, not user solvable. Just try again later and ultimately switch off/on the whole system. ZIP zone required at The FM has popped up a dialog to enter franking machine the ZIP Zone. Job execution will be blocked until a ZIP Zone has been entered. Franking machine An attempt is made to start an FM job from job selected includes the IN. The FM job includes "Dynamic Dynamic batch mode 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.

Page 37 of 38
FPi 4030 / 2000-2

Error
01
Message*
02
Cause
03
Information
04 05 06 07
INF:50
Sealing on advanced feeder of franking machine is selected Sealing on advanced feeder of franking machine is selected Manual clean of cartridge on franking machine failed The franking value exceeded the 'High value threshold'
INF:51
INF:52
INF:53
INF:54
INF:55 INF:56 INF:57 INF:58 INF:59
Franking machine stopped via escape key FIFO Overflow Weight exceeds limit Rate calculation Envelope measures No active rate table
An attempt is made to start an FM job with sealing on AF selected. The user can only solve this by modifying the FM job (disable sealing) or modifying the IN job. An attempt is made to start an FM job with sealing on the MMF/AF selected. This can be overruled through the service menu setting. An attempt to force to clean the cartridge manually failed. Not user solvable! Just try again and pray A job was started in which 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'. The user has to confirm this high value at the FM by either pressing 'OK' or 'ESCAPE'. The user has aborted the franking cycle by pressing 'ESCAPE' at the FM. The job will be aborted. FIFO Overflow for PPC variable mode Check weight values in job settings Rate calculation failure Invalid envelope measure for PPC management No active rate table - probably Base only, activate rate table.
It is recommended to seal through the inserter. This warning is generated when pressing the start key.
When pressing start key. When pressing start key. When pressing start key. When pressing start key. When pressing start key.

Page 38 of 38
Page 64
SERVICE MANUAL FPi 4030 INSERTING SYSTEM Upgrading and installing accessories
Upgrading and installing accessories

7.1 Conveyer stacker (FPi 4030 only)
See separate document: Mounting instructions Conveyer stacker.
7.2
OMR
See separate document: Mounting instructions OMR.
7.3
MaxiFeederTM (FPi 4030 only)
See separate document: Mounting instructions MaxiFeederTM MF2.
7.4
Online services
See separate document: Mounting instructions Connectivity kit and Getting connected.
7.5
Insertn FrankTM (not yet available)
See separate document: Mounting instructions Franking/Mailing interfaces.
7.6
Intermediate transport
See separate document: Mounting instructions intermediate transport.
Release: 07/2006
0 51.0067.1001.00 Page 71
SERVICE MANUAL FPi 4030 INSERTING SYSTEM Upgrading and installing accessories
Page 72
SERVICE MANUAL FPi 4030 INSERTING SYSTEM Technical Specifications
Technical Specifications
8.1 8.1.1 Technical specifications Machine specifications
Model:
FPi 4030
Type:
Inserter system for medium office use
Noise level:
< 70 dB(A) (following ISO 11203)
Power consumption:
100V AC / 50 Hz / 5.0 Amps 115V AC / 60 Hz / 5.0 Amps 230V AC / 50 Hz / 2.5 Amps
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 UL Listed I.T.E. (Information Technology Equipment), conform UL-IEC 60950, file E153801 Conform NEN-EN-IEC 60950 and derivates
Release: 07/2006
0 51.0067.1001.00 Page 81
There are 2 models: FPi 4030: 3 standard feeders FPi 4030 Special: 2 standard feeders and 1 special feeder at the bottom The 2 types of feeders are: 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: not only for special papers such as glossy papers, small booklets pre-folded inserts, but also for normal paper.
Features Number of Feeders: Glossy papers, pre-folded, booklets processing: Daily mail: Automatic fold settings: Full programmable jobs: Feeder swap*: Multi sheet feeder: Securen FeedTM on all feeders: Fill & Start: BRE MaxiFeederTM OMR Levels 1, 2, 3 and Flex: Conveyor stacker: Side exit: Insertn FrankTM Level 1, 2 and 3 **: Adjustable height furniture:
FPi 4030 3 Some, test dependent Yes Yes Yes Yes Yes Yes Yes Option Option Option Option Option Option
FPi 4030 Special 3 Yes Yes Yes Yes Yes Yes Yes Yes Option Option Option Option Option Option
* Not possible in combination with OMR ** availability country/organisation dependent
Page 82
8.1.2
Documents
Paper height:
minimum
90 mm (115 mm for FE-3, unless intermediate transport option is used) 356 mm (14")
maximum
Paper width:
minimum minimum maxi feeder maximum (no fold, no insert) maximum (no fold) maximum with fold
130 mm 140 mm 242 mm 236 mm 230 mm
Paper weight:
minimum maximum without folding: maximum with fold
60 gr/m2 250 gr/m2 170 gr/m2
Brochures:
maximum thickness (no fold) If flexible and back/fold leading into feeder
1 mm
Reply envelopes:
minimum weight minimum size maximum size
80 gr/m2 90x130 mm (height x width), with MF-1/2: 90x140 156x236 mm (height x width)
Set thickness:
Max. number of sheets to be folded: 8 x 80 gr/m2 (single fold) 6 x 80 gr/m2 (letter fold, Z-fold) 3 x 80 gr/m2 (double parallel fold) Max. set thickness to be conveyed through folder: 2.5 mm
Release: 07/2006
0 51.0067.1001.00 Page 83
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. 5-6 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.
Set height:
max.set height 156 mm (or envelope height +/- 6 mm) max set height (with not inserting) 203 mm, and mutual difference address fold and set height/residual length max. 50 mm. min. set height 84 mm min. set height (with not inserting) 102 mm
Kinds of paper:
Normal MC shiny up to and including mat Recycled paper Booklets Prefolded paper: A3 double to A4 A4 folded to A5 or 4" or booklets Reply Envelopes
standard feeder standard feeder standard feeder standard feeder special feeder special feeder 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.
Page 84
8.1.3
Height: minimum maximum
Envelopes
90 mm 162 mm Envelope + flap max. 165 mm
maximum at presentation with open flap:
Width:
minimum minimum
160 mm Set width +12 mm with single sheet, increasing to +28 mm for 8 sheet multiple fold 248 mm
maximum
Flap height:
minimum maximum
32 mm (in middle) envelope height minus 32 mm
Dcollet:
min. 10 mm, on 43 mm from the middle. Outside this may be lower maximum 75 mm
Paper grade:
minimum paper weight: maximum paper weight:
45 gr/m2 120 gr/m2
Release: 07/2006
0 51.0067.1001.00 Page 85
8.1.3.1
Insert specifications
A Minimum size mm inches Maximum size* mm inches 160 6.3 248 9.7
B 90 3.5 162 6.38
C 32 1.25 B-32 B-1.25
D 10 0.4 35 1.4
E 130 5.1 A-12** A-0.47**
F 84 3.3 B-6 B-0.2
G 60 g/m2 60 g/m2 2.5*** 0.1
* Maximum insert specifications are based on single sheets. When multiples are handled, more room inside the envelope is needed depending on the application. ** When insert is more than 1 mm (0.04 inch): A-15 mm / A-0.6 inch *** Booklets up to approximately 1 mm (0.04 inch) thickness, depending on stiffness
Notes 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 machine at least 24 hours before use. Self-copying paper may cause rubber parts to wear quicker. The rubber used in this machine has the best resistance to Wiggins Teape material.
Page 86
8.1.4
Capacity feeders and exit options
Capacity feeder hopper: Capacity BRE MaxiFeederTM: Capacity envelope hopper:
325 sheet 80 grm/m2, this is approximately 3.7 cm 325 reply envelopes 160-170 mm (325 empty envelopes 80 gr/m2)
Capacity envelope exit options:
Catch tray Stacker Stacker+extension Side exit
100 env C5/6 with 1xA4 80 gr/m2 multiple fold 150 env C5/6 with 1xA4 80 gr/m2 multiple fold 300 env C5/6 with 1xA4 80 gr/m2 multiple fold 225 env C5/6 with 1xA4 80 gr/m2 multiple fold
8.1.5
Fold types
The FPi 4030 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 Address carrier loaded in Address face ... Address position
Z-fold Bottom station or Top station Down Trailing
Other folds Top station Up Leading
Release: 07/2006
0 51.0067.1001.00 Page 87
Folding table limitations:
Maximum depth 1st folding table Maximum depth 2nd folding table Minimum depth in 1st and 2nd folding table Minimum distance back of document to fold 2nd folding table, with multiple fold: distance between both folds minus residual length =<
255 mm 150 mm 25 mm 75 mm
105 mm
8.1.6
Processing speed
There are 3 fixed stop positions on the collator. These positions are:
a: A5 b: A4 c: 14"
Page 88
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.
System speed per job:
Feeder 3: Feeder 2: Feeder 1: Fold: 1xA5 E 108 1x11" W 99/ 198 b 2 50 yes #10 (105) 3060 1xA4 W 108/ 216 b 2 50 yes C5/6 (114) 3000 1x14" DP 99/ 198 c 2 50 yes #10 (105) 2500 1xA4 1x100 W 96/ 204 b 2 50 yes C5/6 (114) 2650 1xA4 1xA4 W 108/ 216 b 2 50 yes C5/6 (114) 2650
1xA4 1xA4 1xA4 W 108/ 216 b 2 50 yes C5/6 (114) 2200
3xA4
2xA4 2xA4
1x100 W 106/ 212 b 2 50 yes C5/6 (114) 900
1x100 W 106/ 212 b 2 50 yes C5/6 (114) 900
Collator at: Mode: Doc offset: BRE offset: Envelope: Output/ hour:
a 2 50 yes C5/6 (114) 3500
8.1.7
Length: 765 mm 1120 mm 1260 - 1360 mm 1200 mm Width: Height: 460 mm 680 mm
Configuration dimensions
on covers including hopper (90 mm) and collator /doc.hoppers (265 mm) including standard Exit (catch tray) including side exit (the optional side exit is 90-195 mm outside side cover)
Release: 07/2006
0 51.0067.1001.00 Page 89
8.1.8
Features
System operation control

Performance 20 Central 20mm * 90 mm Resolution: 320 * 240 pixels Full color touch screen
Number of jobs programmable

Fold settings Screen size Screen resolution Screen technology
8.1.9
Features Noise level Operating temperature Operating humidity Power requirements
Other general specifications

Performance <70 sBA (68 dBa) 10 C - 40 C 30% - 80% 230V/50Hz (voltage tolerance: +10%/-10%) 115V/60Hz (voltage tolerance: +6%/-10%) 100V/50Hz (voltage tolerance: +6%/-10%) Whole system: 73 kg
Weight
8.1.10 Quality
Maximum volume per month: 40,000 envelopes
8.1.11 Operating modes

Daily mail (manual feeding) Fold only Insert only Fold + Insert Yes Yes Yes Automatic feeding Yes Yes Yes
Page 810
8.1.12 Optical Mark Recognition

8.1.12.1

Concept
One track OMR code only Factory fitted as well as Field upgradeable Available levels: Level 0, 1, 2, 3 and Flex
8.1.12.2 Reading marks and their meaning by level
Reading code parameter Start mark Start mark Insert on Insert on Divert & Continue Divert & Continue Stop mark Stop mark Selective feed 1 Selective feed 1 Selective feed 2 Selective feed 2 Sequence check Sequence check 3 Sequence check 2 Sequence check 1 Parity check Parity check Safety mark Safety mark Line spacing
Value Yes No Mark Space Yes No Yes No Yes No Yes No No Yes Yes Yes Yes No Yes No 4-10 lpi
Description Start mark No start mark Mark is insert; space is accumulate Mark is accumulate; space is insert Divert mark (not supported) No divert mark (not supported) Stop mark No stop mark Selective feed on station 1 No selective feed on station 1 Selective feed on station 2 No selective feed on station 2 No sequence check Sequence check with 3 marks Sequence check with 2 marks Sequence check with 1 mark
Level 1*, 2*, 3 1*, 2*, 3 0 ,1*, 2*, 3 0,1*, 2*, 3 3 3 2*, 3 2*, 3 2*, 3 2*, 3 2*, 3 2*, 3 3 3 3 3
FP-Level B B 0**,B 0**, B B B B B B B B B B B B B B B B B
Parity check, based on a parity mark 1*, 2*, 3 (even) No parity check Safety mark No safety mark 1*, 2*, 3 1*, 2*, 3 1*, 2*, 3
Line spacing in increments/ decrements of 1/32 Displayed in 2 digits in lpi and mm
Release: 07/2006
0 51.0067.1001.00 Page 811
Notes 1 When some functions are not used, marks will shift up. 2 The divert and continue mark cannot be used. The divert and stop mark will make the set stop before folding in the collating area. 3 Selective enclosures only feed from stations where it is not required to read. 4 Divert and continue and Divert and stop features are mutually exclusive. 5 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. 6 The selective feed marks are always present on the last page of a set. 7 The system always starts feeding pages from the reading feeder, before any of the enclosures. *) Not available from FP. **) USA only.
8.1.12.3 Format of the Marks Minimum character length: 6.3 mm or 3 characters.
8.1.12.4 Reading Head Location The reading head is located in the vertical transport area between FE-2 and FE-3. That means that the FPi 4030 can only read from the top feeder.
8.1.12.5 Options Flexible OMR is also available on the FPi 4030. 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.
8.1.13 Product customisation per country / organisation

There is no product customisation per country specific to FPi 4030 except for the usual differences, for example voltage and plugs.
Page 812
Release: 07/2006
0 51.0067.1001.00 Page 813
Page 814
SERVICE MANUAL FPi 4030 INSERTING SYSTEM Illustrated parts list
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.
Please note The following pages contain a printed version. The current release of the illustrated spare parts list can be looked up online in the Service Knowledge Database (SKD).
Release: 07/2006
0 51.0067.1001.00 Page 91

FPi-4030 Service Manual (Rev.1.2)

Hochgeladen von

Dokumentinformationen

Originalbeschreibung:

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

FPi-4030 Service Manual (Rev.1.2)

Hochgeladen von

Copyright:

Verfügbare Formate

FPi 4030 Inserting System Service Manual Illustrated Parts List Operator Manual

Revision: Item number:

SERVICE MANUAL FPi 4030 INSERTING SYSTEM

Your technical trainers

SERVICE MANUAL FPi 4030 INSERTING SYSTEM

Overview of the Service Documentation

Revision: Item number:

SERVICE MANUAL FPi 4030 INSERTING SYSTEM

SERVICE MANUAL FPi 4030 INSERTING SYSTEM Contents

Contents 1 This Manual.................................................................................................... 1-1

Health, Safety and Environment .................................................................. 2-1

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

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

Revision: Item number:

SERVICE MANUAL FPi 4030 INSERTING SYSTEM Contents

The FPi 4030 inserting system .................................................................... 5-1

SERVICE MANUAL FPi 4030 INSERTING SYSTEM Contents

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

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

Technical Specifications............................................................................... 8-1

Revision: Item number:

SERVICE MANUAL FPi 4030 INSERTING SYSTEM Contents

8.1.6 8.1.7 8.1.8 8.1.9 8.1.10 8.1.11 8.1.12

Illustrated parts list....................................................................................... 9-1 Appendix...................................................................................................... 10-1

FPi 4030 Operator Manual.......................................................................... 11-1

SERVICE MANUAL FPi 4030 INSERTING SYSTEM This Manual

Leading Pane Cycle

Revision: Item number:

SERVICE MANUAL FPi 4030 INSERTING SYSTEM This Manual

Health, Safety and Environment

Symbols on the machine and in the manual

Revision: Item number:

SERVICE MANUAL FPi 4030 INSERTING SYSTEM General description

Revision: Item number:

SERVICE MANUAL FPi 4030 INSERTING SYSTEM General description

SERVICE MANUAL FPi 4030 INSERTING SYSTEM General description

Revision: Item number:

So3 PD3 39 62 CL6/7 PD2 PD4 30 So1 45 46 43

PH11 31 61 CL5 40 29 32 33 41 35 PH6 CL4 MS1 42 36 14 13 27 11 PH9

SERVICE MANUAL FPi 4030 INSERTING SYSTEM

For denominations of all parts, see Section 3.3 Paper flow.

SERVICE MANUAL FPi 4030 INSERTING SYSTEM General description

Revision: Item number:

SERVICE MANUAL FPi 4030 INSERTING SYSTEM General description

SERVICE MANUAL FPi 4030 INSERTING SYSTEM General description

Revision: Item number:

SERVICE MANUAL FPi 4030 INSERTING SYSTEM General description

SERVICE MANUAL FPi 4030 INSERTING SYSTEM General description

Insert and exit track

Revision: Item number:

SERVICE MANUAL FPi 4030 INSERTING SYSTEM General description

SERVICE MANUAL FPi 4030 INSERTING SYSTEM General description

Electronics PCB functions

Revision: Item number:

0 51.0067.1001.00 Page 311

SERVICE MANUAL FPi 4030 INSERTING SYSTEM General description

FPi 4030 070.1/062.2 / FPi 2000-2

For a device with communication board:

FPi 4030 070.1/062.2 / FPi 2000-2

Host Phone RS232 (INF) Connection board Expanded Modem board

Switch mode Power supply ID Tag 24Vdc Motor relay board

SERVICE MANUAL FPi 4030 INSERTING SYSTEM General description

Connection with PC (Concorde application)