DS-75 (075.1) Service Manual r1.0

Service Manual
075.1
Revision: rev. 1.0 - 12/2009

Date: December 2009
rev. 1.0 - 12/2009
075.1
075.1
ii
Service Manual
rev. 1.0 - 12/2009
Service Manual
075.1
Table of Contents
1
This manual ................................................................................... 1-1

1.1
1.2
1.3
Health, safety and environment ..................................................... 2-1

2.1
2.2
2.3
Abbreviations ..................................................................................... 1-1

Terminology ....................................................................................... 1-1
Typographical conventions ................................................................... 1-2
Safety instructions ..............................................................................

2.1.1
General ..................................................................................
2.1.2
Electrical safety .......................................................................
Symbols on the machine ......................................................................
End of life ..........................................................................................
2-1
2-1
2-1
2-1
2-1
General description ........................................................................ 3-1

3.1
3.2
3.3
3.4
3.5
3.6
The system ........................................................................................ 3-1

Denominations ................................................................................... 3-1
Paper flow .......................................................................................... 3-2
Process description .............................................................................. 3-2
3.4.1
Document feeding ................................................................... 3-7
3.4.2
Document transport ................................................................. 3-8
3.4.3
Collating the document set ....................................................... 3-8
3.4.4
Document folding .................................................................. 3-11
3.4.5
Envelope feeding ................................................................... 3-12
3.4.7
Envelope exit process ............................................................ 3-14
Electronics ....................................................................................... 3-15
3.5.1
PCB functions ....................................................................... 3-15
3.5.2
Schematic overview ............................................................... 3-16
3.5.3
Connection with PC (Concorde application) ............................... 3-17
3.5.4
The ID-tag ........................................................................... 3-17
3.5.5
Software package compatibility check ...................................... 3-19
Optional features .............................................................................. 3-19
3.6.1
Reading ............................................................................... 3-19
3.6.2
Flex reading ......................................................................... 3-19
3.6.3
High capacity BRE maxiFeeder .............................................. 3-19
3.6.4
Insertn Frank .................................................................... 3-20
3.6.5
Online services ..................................................................... 3-20
3.6.6
High Capacity Vertical Stacker ................................................. 3-20
3.6.7
Side exit .............................................................................. 3-20
3.6.8
Mail Piece Production Control (MPPC) ....................................... 3-20
rev. 1.0 - 12/2009
iii
075.1
User interface ................................................................................. 4-1

4.1
4.2
4.3
Operator menus ................................................................................. 4-1

Job and supervisor menus .................................................................... 4-1
Service menu ..................................................................................... 4-1
4.3.1
System settings ...................................................................... 4-2
4.3.2
Job settings ............................................................................ 4-3
4.3.3
Service tests .......................................................................... 4-4
4.3.4
Service counters ..................................................................... 4-7
4.3.5
Reading: OMR ........................................................................ 4-8
4.3.6
Reading: BCR ....................................................................... 4-11
4.3.7
Diagnostics .......................................................................... 4-14
4.3.8
Online service ....................................................................... 4-14
4.3.9
Remove blockage .................................................................. 4-15
4.3.10 Sealing on franking machine ................................................... 4-15
The 075.1 ........................................................................................ 5-1

5.1
5.2
5.3
5.4
iv
Service Manual
Transport, storage and installation ........................................................ 5-1

5.1.1
Transport ............................................................................... 5-1
5.1.2
Unpacking, installation and storage ........................................... 5-1
Mechanical description ......................................................................... 5-6
5.2.1
General ................................................................................. 5-6
5.2.2
(Dis)assembly - Covers and plates ............................................ 5-7
5.2.3
(Dis)assembly - Electrical components ..................................... 5-11
5.2.4
(Dis)assembly - Feeder modules and vertical transport right-hand 5-14
5.2.5
(Dis)assembly - Feeders ........................................................ 5-19
5.2.6
(Dis)assembly - Vertical transport ........................................... 5-30
5.2.7
(Dis)assembly - Collating area ................................................ 5-31
5.2.8
(Dis)assembly - Folder ........................................................... 5-34
5.2.9
(Dis)assembly - Main drive mechanism inserter ......................... 5-47
5.2.10 (Dis)assembly - Envelope hopper ............................................ 5-55
5.2.11 (Dis)assembly - Upper unit ..................................................... 5-62
5.2.12 (Dis)assembly - Envelope transport ......................................... 5-69
5.2.13 (Dis)assembly - Envelope sealing and ejection .......................... 5-70
5.2.14 (Dis)assembly - Sensors ........................................................ 5-71
5.2.15 Adjustment .......................................................................... 5-88
Electrical description ......................................................................... 5-99
5.3.1
PCBs ................................................................................... 5-99
5.3.2
Display board ..................................................................... 5-100
5.3.3
Keyboard ........................................................................... 5-101
5.3.4
Motor relay board ................................................................ 5-102
5.3.5
Connection board ................................................................ 5-103
5.3.6
Communication board (optional) ........................................... 5-105
5.3.7
Main board ......................................................................... 5-109
5.3.8
ID-tag (2994504Z) .............................................................. 5-115
Maintenance .................................................................................. 5-116
5.4.1
Preventive maintenance ....................................................... 5-116
5.4.2
160k Service visit ................................................................ 5-117
5.4.3
500k Service visit ................................................................ 5-118
rev. 1.0 - 12/2009
Service Manual
Fault finding ................................................................................... 6-1

6.1
6.2
6.3
6.4
075.1
Resolve problems remotely .................................................................. 6-1

Troubleshooting Online Services ............................................................ 6-2
Error handling inserter ......................................................................... 6-2
6.3.1
Battery errors (BAT) ................................................................ 6-4
6.3.2
MPPC errors (CL) ..................................................................... 6-4
6.3.3
Closer errors (CLS) .................................................................. 6-4
6.3.4
Communication errors (COM) .................................................... 6-5
6.3.5
Collator errors (CT) ................................................................. 6-6
6.3.6
DFC errors (DC) ...................................................................... 6-6
6.3.7
Document feeder errors (DF) .................................................... 6-7
6.3.8
Dongle errors (DG) .................................................................. 6-7
6.3.9
Envelope hopper errors (EH) ..................................................... 6-8
6.3.10 Envelope open errors (EOP) ...................................................... 6-8
6.3.11 Folder errors (FOL) .................................................................. 6-9
6.3.12 Insert errors (INS) .................................................................. 6-9
6.3.13 Job errors (JOB) .................................................................... 6-10
6.3.14 Level detector errors (LD) ...................................................... 6-11
6.3.15 License errors (LIC) ............................................................... 6-11
6.3.16 Motor errors (M) ................................................................... 6-12
6.3.17 Modem errors (MOD) ............................................................. 6-12
6.3.18 Online service errors (OLS) ..................................................... 6-14
6.3.19 Reading head errors (OR) ....................................................... 6-15
6.3.20 Photocell errors (Pxx) ............................................................ 6-15
6.3.21 PCB errors (PBx) ................................................................... 6-18
6.3.22 Pulse disc errors (PD) ............................................................ 6-18
6.3.23 Production control errors (PRC) ............................................... 6-19
6.3.24 Reading errors (RE) ............................................................... 6-19
6.3.25 Machine state errors (SM) ...................................................... 6-22
6.3.26 Stacker errors (STK) .............................................................. 6-22
6.3.27 Switches errors (SW) ............................................................. 6-23
6.3.28 System errors (SYS) .............................................................. 6-23
6.3.29 Transport errors (TR) ............................................................. 6-24
Error handling franking machine ......................................................... 6-25
6.4.1
Communication errors (COM) .................................................. 6-26
6.4.2
External errors (EX) ............................................................... 6-26
6.4.3
Insertn Frank errors (INF) ................................................... 6-27
6.4.4
License errors (LIC) ............................................................... 6-34
6.4.5
Cover switch errors (SW) ....................................................... 6-34
Upgrading and installing accessories ............................................. 7-1
7.1
7.2
7.3
7.4
7.5
7.6
7.7
Reading (barcode en OMR) ...................................................................

MaxiFeeder ......................................................................................
Insertn Frank ..................................................................................
Side exit ............................................................................................
High Capacity Vertical Stacker ..............................................................
Mail Piece Production Control (MPPC) .....................................................
Online services ...................................................................................
7.7.1
Preparations ...........................................................................
7.7.2
Connect the system .................................................................
rev. 1.0 - 12/2009
7-1
7-1
7-1
7-1
7-1
7-1
7-1
7-1
7-2
075.1
Technical specifications .................................................................. 8-1

8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
8.13
vi
Service Manual
Machine specifications ......................................................................... 8-1

Documents ........................................................................................ 8-3
Envelopes .......................................................................................... 8-5
Capacity feeders and exit options .......................................................... 8-6
Fold types .......................................................................................... 8-7
Processing speed ................................................................................ 8-7
Configuration dimensions ..................................................................... 8-8
System operation control .................................................................... 8-8
Other general specifications ................................................................. 8-9
Quality .............................................................................................. 8-9
Reading (Optical Mark Recognition) ....................................................... 8-9
8.11.1 Concept ................................................................................. 8-9
8.11.2 Format of the marks ................................................................ 8-9
8.11.3 Reading head location .............................................................. 8-9
8.11.4 Options .................................................................................. 8-9
Reading (Barcode) .............................................................................. 8-9
8.12.1 Concept ................................................................................. 8-9
8.12.2 Format of the code .................................................................. 8-9
8.12.3 Reading head location .............................................................. 8-9
8.12.4 Options .................................................................................. 8-9
Product customization per country / organization .................................. 8-10
rev. 1.0 - 12/2009
Service Manual
075.1
Illustrated parts list ....................................................................... 9-1

9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
9.13
9.14
9.15
9.16
9.17
9.18
9.19
9.20
9.21
9.22
9.23
9.24
9.25
9.26
9.27
9.28
9.29
9.30
9.31
9.32
9.33
9.34
9.35
9.36
9.37
9.38
Covers, frames, and external parts 1/3 .................................................. 9-2

Envelope hopper 1/2 ......................................................................... 9-10
Envelope hopper 2/2 ......................................................................... 9-12
Envelope separation .......................................................................... 9-14
Lower envelope track 1/2 ................................................................... 9-16
Lower envelope track 2/2 ................................................................... 9-20
Insert table and upper envelope track .................................................. 9-22
Insert and eject mechanism ............................................................... 9-26
Moistening unit ................................................................................. 9-28
Envelope closing mechanism .............................................................. 9-30
Main drive mechanism ....................................................................... 9-32
Feeder/Folder driving mechanism ........................................................ 9-34
Envelope track driving mechanism 1/2 ................................................. 9-36
Envelope track driving mechanism 2/2 ................................................. 9-38
Document feeder unit (automatic) ....................................................... 9-40
Document feeder unit - special 1/2 ...................................................... 9-44
Document feeder unit - special 2/2 ...................................................... 9-46
Document feeder trays ...................................................................... 9-48
Vertical track (base) .......................................................................... 9-50
Vertical track (loc) ............................................................................ 9-52
Collating unit (upper) ........................................................................ 9-54
Collating unit (lower) and power supply ............................................... 9-58
Folder unit (base) ............................................................................. 9-62
Folder unit (loc) 1/4 .......................................................................... 9-64
Folder unit (loc) 2/4 .......................................................................... 9-66
Folder unit (loc) 3/4 .......................................................................... 9-68
Folder unit (loc) 4/4 .......................................................................... 9-70
Electrical components ........................................................................ 9-72
High capacity feeder 1/4 .................................................................... 9-74
High capacity feeder tray ................................................................... 9-82
Side exit 1/3 .................................................................................... 9-84
Side exit 2/3 .................................................................................... 9-86
Side exit 3/3 .................................................................................... 9-88
rev. 1.0 - 12/2009
vii
075.1
10
Appendix ....................................................................................... 10-1

10.1
10.2
10.3
10.4
10.5
10.6
10.7
10.8
viii
Service Manual
Recommended spare parts ................................................................. 10-1

Electrical diagrams ............................................................................ 10-6
Product coding for CRM ................................................................... 10-32
10.3.1 Failure symptoms ................................................................ 10-32
10.3.2 Module .............................................................................. 10-32
10.3.3 Failure origins ..................................................................... 10-33
Checklist training operator ............................................................... 10-39
High Capacity Vertical Stacker .......................................................... 10-43
10.5.1 Process description .............................................................. 10-43
10.5.2 (Dis)assembly - High Capacity Vertical Stacker ....................... 10-44
10.5.3 Preventive maintenance ....................................................... 10-54
10.5.4 Troubleshooting .................................................................. 10-54
10.5.5 Electrical diagram HCVS-1 (2825913J) ................................... 10-55
10.5.6 Parts list ............................................................................ 10-56
10.5.7 Recommended spare parts HCVS-1 ....................................... 10-65
10.5.8 Specifications High Capacity Vertical Stacker .......................... 10-66
Total view electronics sheet 1/3 ........................................................ 10-67
rev. 1.0 - 12/2009
Service Manual
1
This manual
1.1
075.1
Abbreviations
Abbrev. Explanation
Abbrev.
Explanation
BRE
Business Reply Envelope
ISIS
Interface Standard Inserting Systems
CCW
Counter Clockwise
LH
Left Hand
CW
Clockwise
MPPC
Mail Piece Production Control
DFC
Double Feed Control
MS
Mailing System
DS
Document System
OLS
OnLine Services
FM
Franking Machine
OMR
Optical Mark Recognition
GUI
Graphical User Interface
PCB
Printed Circuit Board
HMI
Human Machine Interface
RH
Right hand
I2C
Inter-Integrated Circuit
SCS
Serial Communication System
INF
insertn Frank
UI
User Interface
1.2
Terminology
Term
Description
Double Feed
Control (DFC)
Double Feed Control measures the thickness of a sheet to check if the

inserting system does not accidentally take more sheets than intended. DFC
sensors exist on feeders (double sheet detection). DFCs on the inserting
systems perform relative measurements, which means that they need a
cycle to 'learn' the thickness of a sheet.
Also the length of the document is measured so partly overlapping sheets
will be detected.
Leading
Situation in which the top of the sheet is closest to the separation unit in a
document feeder.
Pane Cycle
The various documents of a set are fed from the feeders in such a way that
these documents are partly overlapping each other. This pane-like
overlapping ensures a higher throughput.
Sequential Cycle
Documents are transported along the vertical track without touching each
other. Only after joining the set in the making they do touch each other.
Shunting
The partially completed set in the collator is moved from the collator area
in the direction of the fold unit (short shunt) or into the fold unit (long
shunt). See 3.4.3 Collating the document set on page 3-8.
Trailing
Situation in which the bottom of the sheet is closest to the separation unit
in a document feeder.
rev. 1.0 - 12/2009
1-1
075.1
1.3
Service Manual
Typographical conventions
Warning
This symbol identifies situations where improper use of the machine can result in
personal injury or permanent/catastrophic damage to the machine.
Warning
This symbol identifies situations in which electrical hazard exists.
Note
A note gives additional relevant information.
1-2
rev. 1.0 - 12/2009
Service Manual
2
Health, safety and environment
2.1
Safety instructions
2.1.1
075.1
General
This machine must be operated by competent personnel.

The manufacturer accepts no responsibility for accidents or injuries caused by operation by
incompetent personnel.
Covers may only be opened by skilled persons, who know the risks involved.
For safety reasons, the machine will not function with opened covers.
Keep away long hair, fingers, jewelry, etc. from rotating and moving objects of the system.
Switch off the system at the end of the day.
2.1.2
2.2
Electrical safety
The power connection must be easily accessible, preferably close to the machine.
For safety reasons it is essential that the machine is connected to a socket outlet with
protective earth connection.
Over-current protection in the equipment also relies on the branch circuit protection (max.
20 A).
Disconnect the machine from the power supply when it is not in use for a longer time.
Potential hazard may exist to electronic hardware in conditions with static electricity. It is
advised that, when handling electronic parts, an earth connected wrist band is used in order
to be permanently discharged from static electricity.
Symbols on the machine

Warning
This symbol identifies situations where improper use of the machine can result in
personal injury or permanent/catastrophic damage to the machine.
2.3
End of life
The objectives of the European Community's environment policy are, in particular, to preserve,
protect and improve the quality of the environment, protect human health and utilise natural
resources prudently and rationally. That policy is based on the precautionary principle and
principles that preventive action should be taken, that environmental damage should as a
priority be rectified at source.
Separate collection of waste is the precondition to ensure reuse and recycling of waste that is
generated at the disposal of electrical or electronical equipment and is necessary to achieve the
chosen level of protection of human health and the environment in the European Community.
More particularly, certain materials and components of waste electrical and electronical
equipment needs selective treatment as their injudicious handling or disposing of on or into land,
water or air would represent a major threat to the environment and human health.
rev. 1.0 - 12/2009
2-1
075.1
Service Manual
In order to facilitate collection and treatment separated from normal domestic waste, electrical
and electronical equipment is marked with the following logo:
Do not mix with normal domestic waste
Please use the subjoined return or
collection system dedicated to electrical
and electronical waste.
Equipment produced after August 13,

2005.
Not only are you by law not allowed to dispose of the waste equipment via other waste-streams,
but we encourage you to actively contribute to the success of such collection and to the common
good and better quality of life of present and future generations.
For more information on the correct disposal of this product please contact your local dealer.
2-2
rev. 1.0 - 12/2009
Service Manual
3
General description
3.1
075.1
The system
The 075.1 feeds, folds and inserts documents into envelopes and then seals and stacks the
envelopes.
The system is equipped with a variety of special features as programmable jobs, loadn Go,
flexFeed, double feed control, hopper swap, multifeed, daily mail, powerFold, and automatic
collator stop positions.
3.2
Denominations
E
A
H
I
T
A
B
C
D
E
F
G
H
I
J
catch tray
envelope slide
display with operating buttons
upper unit
locking hand grip upper unit
document feeder tray
collator arm
collating area
power inlet, power switch,
RS232 connector / USB / modem
handles for clearing stoppages
rev. 1.0 - 12/2009
J L K J
K
L
M
N
O
P
Q
R
S
sensors
bellows
unlocking handle for rollers envelope track
water reservoir
side cover (opened)
ruler
thumb wheel for side guide adjustment
side guides envelope hopper
handle for separation adjustment
Envelope support bracket
3-1
075.1
3.3
Service Manual
Paper flow
2
5
3
6
4
The documents are vertically transported from the document feeder(s) (1) to the collator (2).
When the required documents are collected, the document pile is transported horizontally to the
document folder (3). After folding, the documents are inserted into an envelope by the inserter
(5). Finally, the envelope is sealed and transported to the envelope receiving tray.
3.4
Process description
The processing of documents by the system can be divided into a number of distinct sequential
partial processes. These processes will be discussed in some more detail:
Document feeding
Document transport
Collating the document set
Document folding
Envelope feeding
Inserting process
Envelope exit process

The figure on the next page shows a schematic overview of the process. All mechanical items
that are strictly necessary to explain the process are projected on the left-hand side of the
machine. This implies that not all auxiliary mechanical items (such as gears and belts) are
shown.
See Section 5.2 Mechanical description and Section 9 Illustrated parts list for more details
on the mechanics.
3-2
rev. 1.0 - 12/2009
rev. 1.0 - 12/2009
MS2
PD1
PH4
RX
TX
19
22
23
20
21
PH5
TX
RX
24
25
CL8
So3
So4
18
17
26
So2
15
16
10
TX
PH1
RX
13
TX
RX
14
11
So1
9a
PH3
RX
12
PH2
TX
PD2
31
27
28
29
30
34
33
32
CL6/7
PD3
39
35
36
37
38
M2
41
40
PH7
CL4
77
78
TX
RX
45
TX
46
CL5
CL1
63
64
TX
TX
DFC1
70
71
DFC2
TX
RX
PH6
44
61
PH9
RX
68
PH10
RX
75
PH11
42
43
62
CL2
69
RX
76
CL3
MS3
DFC3
MS1
47
PH8
TX
M1
PD4
65
66
72
73
79
80
48
67
74
81
49
50
51
52
FE1
FE2
FE3
53
54
56
55
57
58
59
60
Service Manual
075.1
3-3
075.1
Service Manual
Rollers
No.
Description
Feed roller. Activated by the envelope track clutch CL8.
Separation roller.
3, 5, 7
Counter rollers for 4, 6 and 8. These rollers can be moved by the release handle in case
of a paper jam in the envelope track.
4, 6, 8
Driven envelope transport rollers. Activated by the envelope track clutch CL8.
9, 12
Counter rollers for 10, 11. These rollers can be moved by the release handle in case of
a paper jam in the envelope track.
9a
Friction brake.
10
Driven envelope transport roller (flap opening stage). Activated by the envelope track
clutch CL8.
11
Driven envelope transport roller (flap opening stage). Activated by the envelope track
clutch CL8.
13
Lower insert roller.
14
Upper insert roller (in the upper unit).
15
Lower first ejection roller. On the axle at the LH side of the machine the LH hand knob
is mounted. On this axle at the RH side of the machine the main pulley is mounted.
16
Upper first ejection roller (in the upper unit). Lowered by the action of the insert table
solenoid So2.
17
Lower second ejection roller. In this area the moistening brushes are located.
18
Upper second ejection roller (in the upper unit).
19
Driven sealing track roller. On the axle at the RH side of the machine the pulse disc PD1
(monitored by slotted photocell SPH1) is mounted.
20
Driven sealing track roller.
21
Counter roller for 22 (in the upper unit).
22
Lower sealing roller. A gear on the axle (on the RH side of the machine) provides via an
intermediate gear the mechanical interface to all the driven parts in the upper unit (14,
16, 24, 26). Directly driven by M2.
23
Upper sealing roller.
24
Lower reverse roller (in the upper unit).
25
Upper reverse roller (in the lower unit). Lowered by the action of the sealing solenoid
So3.
26
Drive rollers for future use.
27
Lower fold roller for second fold table.
28
Upper fold roller for second fold table. In upper unit.
35
Lower fold roller for first fold table.
36
Upper fold roller for first fold table. In upper unit.
3-4
rev. 1.0 - 12/2009
Service Manual
075.1
No.
Description
42
Lower fold input roller. On this axle on the RH side the folding forward clutch CL4 is
mounted. This clutch drives 42, 43, 35, 36, 27 and 28. Operational during the fold
process and during the first stage of a long shunt.
43
Upper fold input roller.
44
Counter roller of 45 (in the upper unit).
45
Driven vertical transport axle. On this axle the folding reverse clutch CL5 is mounted
(at the RH side of the machine). This clutch drives 42, 43, 35, 36, 27 and 28 in the
reverse direction during the second stage of a long shunt.
46, 50, 53, 56,

60
Collator rollers driven (either forward or reverse) by the collator motor M1. In collator
arm.
47, 48, 49, 52,

54, 55, 58
Free running collator rollers.
61
Driven vertical transport axle. On this axle feeder 1 (lower) clutch CL1 is mounted (at
the LH side of the machine). This clutch drives 63, 65 (only in feeder with manual
separation), 66 and 67.
62
Counter rollers for 61 (in upper unit).
63
Driven output rollers.
64
Counter rollers for 63.
65
Lower separation roller. Turns CW in feeder with manual separation.
66
Feed axle with upper separation roller.
67
Paper puller axle with two rubber rollers.
68
Driven vertical transport axle. On this axle feeder 2 (middle) clutch CL2 is mounted (at
69
70
71
72
73
74
75
Driven vertical transport axle. On this axle feeder 3 (upper) clutch CL3 is mounted (at
76
77
rev. 1.0 - 12/2009
3-5
075.1
Service Manual
No.
Description
78
79
80
81
Photocells
No.
Description
PH1
Envelope track cell
PH2
Flap cell
PH3
Insert table cell
PH4
Exit cell
PH5
Closer cell
PH6
Folder entry cell
PH7
Vertical track cell
PH8
Collating area cell
PH9
Feeder cell
PH10
Feeder cell
PH11
Feeder cell
Clutches
No.
Description
CL1
Feeder clutch. Drives 61, 63, 65 (only in feeder with manual separation), 66 and 67.
CL2
CL3
CL4
Fold forward clutch. Used during a fold cycle and in the first stage of a long shunt.
CL5
Fold reverse clutch. Used in the second stage of a long shunt.
CL6
First fold table clutch. Drives 37.
CL7
Second fold table clutch. Drives 29.
CL8
Envelope track clutch. Mounted on clutch shaft, at the RH side of the machine. On this
shaft two gears take care for the mechanical interface between the permanently M2
driven subsystem and the envelope track subsystem. CL8 drives 1, 4, 6, 8, 10 and 11.
3-6
rev. 1.0 - 12/2009
Service Manual
075.1
Solenoids
No.
Description
So1
Finger solenoid. Moves the fingers into the envelope when the envelope is on the insert
table.
So2
Insert table solenoid. Moves the ejection roller 16.
So3
Sealing solenoid. Moves roller 25 to transport the envelop to the sealing rollers.
So4
Brush solenoid. Lowers the brush to moisten the envelope flap.
3.4.1
Document feeding
DFC3
FE3
RX
PH11
78
77
80
81
79
TX
CL3
FE2
RX
RX
TX
TX
FE1
RX
TX
Rollers 79 - 81 separate the document for feeder 3.

Rollers 77 and 78 exit this document to the vertical track. DFC unit 3 measures the
thickness.
Photocell PH11 monitors the document.
Clutch CL3, driven by main motor M2, drives feeder 3.
rev. 1.0 - 12/2009
3-7
075.1
3.4.2
Service Manual
Document transport
FE3
RX
TX
CL3
76
FE2
75
RX
PH7
RX
69
TX
TX
FE1
68
CL2
RX
PH9
TX
62
CL1
61
CL5
44
45
M1
TX
RX
TX
12
27
34
35
Depending on the number of documents to be delivered by each feeder there are two ways in
which documents can be transported along the vertical track: pane cycle and sequential cycle.
Pane Cycle:
The various documents of a set are fed from the feeders in such a way
that these documents are partly overlapping each other. This pane-like
overlapping ensures a higher throughput.
Sequential Cycle: Documents are transported along the vertical track without touching
each other.
When reading is on the sequential cycle is used.
The vertical track consists of one driven roller per feeder (75, 68, 61), plus one driven roller
in the lower vertical track (45).
The driven rollers have their counterparts in rollers 76, 69, 62 and 44.
If the OMR option is installed, the document transport is monitored by the reading head
photocell (PH7). This monitoring is necessary to establish the reading window.
3.4.3
Collating the document set
The following rules apply to the way in which a set is composed (collated):
The highest active feeder is processed first, the lowest active feeder last. This is
independent of the fold type.
3-8
rev. 1.0 - 12/2009
Service Manual
075.1
If a feeder adds two or more documents to a set (multi-feeding), these documents are first
processed.
PH10
RX
70
72
TX
TX
FE1
RX
TX
PD4
CL5
44
M1
45
46
43
48
RX
TX
50
PH8
TX
49
53
51
52
56
54
55
57
59
60
58
47
42
PH6
CL4
The collating area consists of a set of rollers (46, 50, 53, 56 and 60) that can be driven in
both directions by the collator motor (M1).
In the reverse direction of the collator motor documents are fed into the collator area. In
the forward direction they are moved out.
Collating area photocell (PH8) monitors the entry of the paper into the collator area (not the
leaving of paper!).
The documents are aligned against the relevant automatic document stoppers (51, 57 or
59).
Before a sheet is added to the set, the set moves out of the collator to prevent collision of the
document against the set. When the document is added to the set the set moves back into the
collator. The moving into and out of the collator is called shunting. The system can perform a
long shunt or a short shunt. This depends on the mode selection (see System output on
page 4-3).
rev. 1.0 - 12/2009
3-9
075.1
Service Manual
Short shunt (mode 2)
1
2
3
4
PH8 detects a document in the document transport. The transport stops.

M1 runs in the forward direction: the partially completed set is moved over a short distance
to the fold table.
The document transport starts again and moves the document into the collator. M1 runs in
reverse direction and moves the set back into the collator.
The document moves over the set until it is aligned with the set against the paper stop.
Mode 2 focuses on minimal necessary paper displacement. This implies a higher processing
speed. However there is longer paper contact between the new entering document and the
partially completed set.
Long shunt (mode 1)
1
2
3
PH8 detects a document in the document transport. The transport stops.

M1 runs in the forward direction and CL4 is activated: the partially completed set is moved
into the fold table.
The document transport starts again. M1 runs in reverse direction and CL5 is activated.
3-10
rev. 1.0 - 12/2009
Service Manual
075.1
The document and the set move together into the collator until they are aligned against the
paper stop.
Mode 1 takes more time, but the paper-to-paper contact occurs over shorter distances.
When the set is complete M1 (forward direction) and CL4 are activated and the set is moved into
the fold unit.
3.4.4
Document folding
TX
PD3
31
39
CL6/7
PD2
38
30
40
29
TX
28
14
32
33
37
43
36
TX
13
RX
27
34
35
41
42
PH6
CL4
RX
RX
TX
TX
M2
The paper of a completed set leaves the collator area. This is detected by the folder entry
photocell (PH6).
3.4.4.1 First fold
The fold input rollers (42 and 43) transport the paper to the first fold table. The flap (41)
moves up. Paper that enters the first fold table will be directed in upward direction.
At the appropriate time, the flap (41) moves back and the fold plate (40) moves forward.
This is the first fold.
Directly after the fold has been made, the fold plate (40) returns to its rest position. The
movement of the fold plate (40) and the flap (41) is controlled by the first fold table clutch
(CL6). The clutch drives the curve gear (37). The axle for the curve gear also carries the
brake disc (38). Slotted photocell (SPH3) monitors the status of the curve gear.
The 360 degrees fold cycle of the brake disk consists of a 120 degrees part (flap upwards)
and a 240 degrees path (flap downwards plus karate action of 40). The brake disc is
mechanically loaded by a positioning lever and a torsion spring. The hinge axle (39) also
carries the lever for the actuator of flap 41. In this way all movements related to the first
fold table are synchronized.
3.4.4.2 Second fold
After leaving the fold rollers (35 and 36), the paper enters the second fold table. The flap
(34) moves up. Paper that enters the second fold table will be directed in upward direction.
The paper guide (33) also moves up. This guide is necessary in the second fold table to
retain the fold that has been made in the first fold table.
The paper is limited to a small area between the paper guide (33) and a fixed vertical guide
plate (not shown in the figure, but to the left of 33).
At the appropriate time the flap (34) moves back and both the fold plate (32) and the guide
plate (33) move forward. This is the second fold.
rev. 1.0 - 12/2009
3-11
075.1
Service Manual
Directly after the fold has been made, the fold plate (32) returns to its rest position. The
movement of the fold plate (32), the paper guide (33) and the flap (34) is controlled by the
second fold table clutch (CL7). The clutch drives the curve gear (29). The axle for the curve
gear also carries the brake disc (30). The slotted photocell (SPH4) monitors the status of
the curve gear.
The 360 degrees fold cycle of the brake disk consists of a 120 degrees part (flap and paper
guide upwards) and a 240 degrees path (flap and paper guide downwards plus karate
action of 32). The brake disc is mechanically loaded by a positioning lever and a torsion
spring. The hinge axle (31) also carries the lever for the actuator of flap 34. In this way all
movements related to the second fold table are synchronized.
Finally the paper leaves the fold unit on its way (transported by 27 plus 28 and 13 plus 14) to
the insert table.
The timing of the fold plate movement is based on the detection of the paper by the folder entry
photocell PH6, on machine parameters and on operational fold parameters.
3.4.5
Envelope feeding
TX
RX
TX
RX
TX
12
RX
11
RX
PH2
6
9
7
TX
10
8
2
9a
RX
CL8
TX
5
PH1
All the rollers for this process stage (1, 4, 6, 8, 10 and 11) are engaged to the main drive
by the envelope track clutch (CL8). During the document and insert stage these rollers are
disengaged.
The feed and separation rollers (1 and 2) separate an envelope from the stack in the hopper.
The envelope is transported via three pairs of transport rollers (3 - 8). The envelope track
photocell (PH1) detects the leading and trailing edge of the envelope.
The envelope then passes the flap rollers (9 and 10).
The combined action of the flap scraper and the lower linear speed of the flap rollers (9 to
12) compared with the speed of rollers 3 to 8, results in some buckling and the opening of
the envelope.
The flap is the trailing part of the envelope passing the flap rollers and the flap photocell
(PH2).
Pulse measurements (measured via slotted photocell SPH1) during the presence of the
envelope under the photocells (PH1 and PH2) provide information on:
The length of the not yet opened envelope
The length of the opened envelope
3-12
rev. 1.0 - 12/2009
Service Manual
075.1
The time at which the envelope transport is suddenly stopped with the envelope on the
insert table
The sudden stop is the result of disengaging by the envelope track clutch (CL8) and the
friction brake (9a). The envelope flap now is fixed between two rollers (11 and 12).
In the final ejecting, sealing and exiting stage the driven rollers are engaged once again to
release the envelope (held between 11 and 12) and to feed a new envelope to the insert
table.
3.4.6
Inserting process
So1
TX
14
12
13
RX
11
PH3
RX
9a
RX
TX
TX
Once the envelope is on the insert table, the fingers solenoid (So1) is activated. The fingers
are moved forward into the envelope. The envelope stays in place, it is fixed between the
two rollers (11 and 12).
Now the document set is inserted. The set leaves the fold unit (transported by rollers 27
plus 28 and by 13 plus 14), is detected by the insert table photocell (PH3) and passes below
the fingers before it enters the envelope.
When the insert table photocell (PH3) detects the trailing edge of the set, the set is inserted.
rev. 1.0 - 12/2009
3-13
075.1
3.4.7
Service Manual
Envelope exit process

TX
So3
PH5
RX
23
25
TX
MS2
24
22
26
21
RX
PH4
So4
PD1
So2
20
TX
16
14
18
19
12
13
15
RX
11
17
PH3
RX
CL8
RX
TX
TX
The clutch (CL8) is activated to release the flap (roller 11 and 12) and to feed a new
envelope to the insert table. The insert table solenoid (So2) moves the ejection roller (16).
Now the envelope is ejected from the insert table. So2 is deactivated after the complete
passage of the filled envelope.
The filled envelope passes rollers 17 and 18. If sealing is on, So4 is activated and lowers
the moistening brushes. The envelope passes the sealing track rollers (19 and 20) and the
lower sealing roller (22) plus its counter roller (21).
Now the photocell (PH5) is triggered. The upper reverse roller (25) is held up by a spring.
A certain time after triggering PH5 the sealing solenoid (So3) is activated. The envelope is
between the upper and lower reverse rollers. So3 lowers reverse roller 25. Given the turning
direction of the lower reverse roller (24), the transport direction of the envelope is abruptly
changed.
The envelope is transported through the sealing rollers 22 and 23. After passing the sealing
rollers the envelope exits the system.
The exit photocell (PH4) monitors the passing envelope.
3-14
rev. 1.0 - 12/2009
Service Manual
3.5
Electronics
3.5.1
075.1
PCB functions
The functions of the PCBs from the schematic overviews can be described as follows:
Board name
Function
Display board
Converts received data into understandable data for the display
Key board
Contains the start and stop buttons
Motor relay board
Turns the motor on and off
4a
Connection board
Provides connection to USB, RS232 and the phone line (see note)
4b
Modem board
(optional)
Converts digital data (from the processor) into analogue data (for
external communication) and the other way around
Communication board
(optional)
Controls the franking interface and external communication
Main PCB
Operates the device and controls the user interface
ID-tag
Contains information (serial number, encrypted machine options,

encrypted total counter)
Note
The regular connection board only provides connection to USB. The expanded connection board
also provides connection to RS232 and the phone line.
See Section 5.3 Electrical description for the location of the PCBs in the system.
rev. 1.0 - 12/2009
3-15
075.1
3.5.2
Service Manual
Schematic overview
The electronics and the wiring between the boards in the 075.1 can be summarized in a
schematic overview.
For a device without communication board:
Host
075.1
Display board
Keyboard
USB cable
Connection board
regular
USB device
Main PCB
Switch mode
Power supply
ID Tag
Motor relay
board
24Vdc
100/115,230V ac
For a device with communication board:
Host
075.1
Phone
Display board
Keyboard
Host
USB
device
Main PCB
ID Tag
Communication
board
RS232
(INF)
USB
cable
Connection board
Expanded
serial
Switch mode
Power supply
24Vdc
Modem
board
Motor relay
board
100/115,230V ac
3-16
rev. 1.0 - 12/2009
Service Manual
3.5.3
075.1
Connection with PC (Concorde application)
If you want to upgrade the inserter software or backup information from the inserter, the
inserter can be connected to a PC. Special software has to be installed on the PC to enable
communication between the USB port of the PC and the machine. This application is called
Concorde.
The
primary functions of Concorde are:

To flash software packages in a complete system (with multiple boards)
To flash new software directly on a board (factory flash)
To backup inserter information and export it to XML format
To restore information into the inserter from a previous backup
The Concorde application has been developed in such a way so that it requires minimal upgrades
in the future. For more information, please see the online help contained in the Concorde
application.
3.5.4
The ID-tag
Each time the 075.1 is started, the presence of the ID-tag is checked.
If the ID-tag is not present, all software controlled options are switched off.
rev. 1.0 - 12/2009
3-17
075.1
Service Manual
If the ID-tag is present, its serial number is compared to the serial number in the FRAM
(refer to the following schedule) and the options are read out.
Start up: Read ID-TAG and FRAM
OK
Serial
number ID-TAG
= Serial number
FRAM
Yes
ID-TAG
count=FRAM
count
No
No
Define
latest
counter
Yes
TAG
correct
Copy
ID-TAG Counter to
FRAM
FRAM
correct
Copy
FRAM Counter to
ID-TAG
System blockage error

Call Service
System deblockage in
service menu
OK
Has the
main board been
replaced only?
Yes4
Synchronize
ID-TAG
Counter to FRAM
Copy
Serial number
ID-TAG to FRAM
Yes5
Set Counter
manually (ID-TAG
and FRAM)
Copy
Serial number
ID-TAG to FRAM
No
Have
the ID-TAG
and the main board
been replaced?
END
In this schedule, number 1 to 5 can be described by:

1
Normal situation
If either FRAM or TAG has been disconnected, the latest counter can be used.
Replacement of PCB or replacement of both the ID-Tag and PCB.
PCB replacement (Tag OK).
PCB and ID-Tag replacement (new ID-Tag)
Note: if incorrect Tag is installed, software controlled options and connectivity will
not function correctly.
3-18
rev. 1.0 - 12/2009
Service Manual
The
075.1
following information is stored on the ID-tag:

Serial number of the machine.
Encrypted machine options.
Total insert counter (kept up to date when the 075.1 is running).
3.5.5
Software package compatibility check
For all systems with (optionally) multiple boards and software versions, NTBV will release
packages that contain the supported software versions of each board. The following matrix may
be applicable (EXAMPLE!):
Examples
Main PCB
Communication board
Package 1
version A
version A
Package 2
version A
version B
Package 3
version B
version B
Each software file contains all compatible software versions of the partner boards. The system
will compare all available software files to know what the highest supported software package
is. It is then decided whether the selected software versions are a valid combination or not.
3.6
Optional features
3.6.1
Reading
With this option, computer printed documents can be handled fully automatically. Optical Mark
Recognition (OMR) and Barcode Reading (BCR) codes are possible.
A code is printed on each document, that contains information about the processing of the
sheets.
The code on the last sheet of the set always contains the insert instructions.
The other sheets carry the accumulate instruction.
If a parity check is used, this is checked on each sheet (only OMR).
The code must appear in the same location on every page regardless of the actual code
length.
Reading can be activated by a system specific license code. You can find further information on
reading in 4.3.5 Reading: OMR on page 4-8 and 4.3.6 Reading: BCR on page 4-11.
3.6.2
Flex reading
With this option, also non-Neopost (customer specific) codes and alternative document handling
algorithms can be recognised. Flex reading can be activated by a system specific license code
and by a customer specific setting that is saved in a physical dongle.
3.6.3
High capacity BRE maxiFeeder
The maxiFeederTM is a feeder that can be loaded with a high number of documents. This feeder
is intended to be used for Business Reply Envelopes (BRE), but also standard documents up
to 156 mm length can be processed with it. The maxiFeederTM is auto-detected by the system
when it is switched ON. This makes it easy to switch over from the standard document feeder
to the maxiFeederTM and vice versa.
To make use of a maxiFeederTM it is not necessary to (re-)program the jobs.
rev. 1.0 - 12/2009
3-19
075.1
3.6.4
Service Manual
Insertn Frank
With this option, in line franking by a connected franking machine can be realised. When a
functioning communication line with the franking machine is present, it is also possible to set
the franking machine and to select a franking job.
Insertn Frank can be activated by a system specific license code. In order to do this, the
communication board and the modem board need to be installed.
3.6.5
Online services
Online services enable the Sales Organisation to remotely manage and maintain a system that
is installed at the customer.
This option needs to be activated per system by the sales organisation. In order to do this, the
communication board and the modem board need to be installed.
3.6.6
High Capacity Vertical Stacker
The High Capacity Vertical Stacker is used to stack filled envelopes. The High Capacity Vertical
Stacker can store up to 325 filled envelopes. The High Capacity Vertical Stacker can be equipped
with Mail Piece Production Control (MPPC).
3.6.7
Side exit
The system can be equipped with a side exit and catch tray. The side exit can be fitted instead
of the standard envelope receiving tray. The side exit allows a conveyor or a franking system to
be fitted in line with the system.
The side exit can also be used with a receiving tray which is delivered with the side exit. The
receiving tray can be fitted to the left or to the right of the side exit to achieve vertical stacking.
3.6.8
Mail Piece Production Control (MPPC)
The folding and inserting system can be equipped with Mail Piece Production Control. This option
enables the system to verify the inserted documents or sets of documents with a database,
which is generated when you print the documents. The system gives a warning when a mail
piece is missing at the exit of the inserter.
3-20
rev. 1.0 - 12/2009
Service Manual
4
User interface
4.1
075.1
Operator menus
For an explanation of the Operator menus, see the Operator Manual.
4.2
Job and supervisor menus
For an explanation of the Job menu and Supervisor menu, see the Operator Manual.
4.3
Service menu
See the following flowchart for an overview of the various menus:

Menu
Supervisor Menu
4351
2546
Supervisor menu
(See operator manual)
Service Menu
Remove
blockage
System
settings
Service
tests
Diagnostics
Online
services
OMR
Start test
Server
settings
Power up
System
output
BCR
Error
counter
Reset CB
data
Folder
offset
Document
offset
Test CB
Flap closer
offset
BRE offset
Actuator
tests
Configuration
Secure jobs
Run in
Localisation
Flap closer
Sealing on
franking
machine
Digital
inputs
Last
error list
Service
counters
Photocells
DFC test
Reading
Job settings
Software
versions
Reset data
Envelope
only mode
Folder
ratio
rev. 1.0 - 12/2009
Touch
screen
Stop key
4-1
075.1
4.3.1
Service Manual
System settings
Power up
In this menu you select if you want to display the language menu after you switch on the system.
Folder offset
Two timed cams discs are used for the folding process. There is one cam disc for each folding
table. The timing is determined by the length of the sheets to be folded.
Given tolerances in the activation times of the clutches involved, this menu provides for an
equivalent shift in the folding positions to compensate a clutch activation time that deviates from
the average value.
In the folder offset menu:
1
2
3
Select the folder.

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

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

Currently the options are: English USA, English UK, Dutch, French, German, Spanish, Italian, Katakana, Swedish, Norwegian, Danish, Portuguese, Russian, Hungarian and Czech.
the service telephone number
the document standard size
machine type
date format
Software versions
The software version screen shows the software versions that are present in the total system.
Reset data
There may be situations in which it is necessary to restore the system settings to their states at
the beginning of the systems operational life. To this purpose the menu item Reset Data is
present.
Make sure all paper is removed from the machine, before you start Reset data. This is necessary
because the data resetting includes readjusting of the photocells.
Press Reset counters to reset all counters (daily counter, counter since last service visit and
counters for the envelope hopper and feeders).
4-2
rev. 1.0 - 12/2009
Service Manual
075.1
Press Reset data to start the reset process. This results in clearing all the data in the FRAM
memory of the system.
If you want to restore the default data in mm and ISO values, press Load defaults mm.
If you want to restore the default data in inches, press Load defaults inch.
Note 1: The changes made by this reset data operation are irreversible! All changes
made on the previous factory settings will be lost.
Note 2: The value of the counter Since installation, the Last error list and the Error
counter are not deleted when you restore the system.
Folder ratio
The folder ration determines the speed at which the document set enters the folding table. The
folder ratio is the ratio between pulses and mm. The ratio can be adjusted between 0.940 and
0.950. The optimum value is 0.945.
4.3.2
Job settings
System output
Use this menu to select operating mode Mode 1 or operating mode Mode 2, for each of the jobs
and loadn Go. Mode 2 is the default setting.
Mode 1 focuses on the versatility of paper parameters (paper thickness; document length),
i.e.: ensures for correct operation even under the most extreme paper conditions. Mode 1
should be used for a paper thickness of 65 g/m or less or a document length of 12 inch or
higher.
Mode 2 focuses on high speed. Mode 2 should be used for all other jobs.
See 3.4.3 Collating the document set on page 3-8 for an explanation of Mode 1 and Mode 2.
Document offset
The vertical transport of documents fed by the various feeders is arranged in such a way that
the documents are partially overlapping each other. This overlapping scheme ensures that the
documents are properly aligned in the collator area.
In the document offset menu you can set the extend to which the documents are not
overlapping each other, i.e. the document offset value. The default value is 50 mm (2.0 inch).
The document offset can be varied between 20 mm (0.8 inch) and 75 mm (3.0 inch).
BRE offset
If a document is longer than the set address fold but shorter than the envelope height, this
document sometimes will be unnecessarily folded. Under certain conditions this document can
be prevented from being folded. This can be implemented with the menu BRE offset (BRE
means Business Reply Envelope).
For each of the jobs 1 through 25 and Lng (loadn Go) an offset can be switched on or off using
the arrow button.
In the case of offset on the last document that had been added to the set prior to further
processing will be shifted from the rest of the set (offsetting), i.e. this document will be held
back during a certain distance. This means that the trailing edge of this upper document leaves
the collator last. This document will not be folded. During insertion into the envelope the
documents of the set will be realigned.
The conditions are:
The feeder that supplies this upper document (BRE) is set to one document per set (no multi
feeding).
rev. 1.0 - 12/2009
4-3
075.1
Service Manual
The document directly beneath this document must be at least 60 mm (2.4 inch) longer
than the BRE.
The upper document must be longer than the set address fold.
The folding mode is either single fold or letter fold (no Z-fold).
The upper document must be shorter than the envelope height.
Note: It is possible to use the BRE offset for a BRE and an enclosure (card) in one set.
The extra condition is that this enclosure is equal to or smaller than the set address fold
and should be placed direct underneath the BRE in the set.
The whole BRE offset is based on friction between documents within a set. Therefore it is
necessary to make use of these conditions to reduce the risk of bad transporting, folding and
inserting.
In some cases the BRE option is automatically switched off if one or more of the abovementioned conditions are not met. Therefore it is safe to switch the BRE option on, unless this
option will never be used.
Secure jobs
With the Secure job menu the selected job can be secured, i.e. locked. This job can not be
deleted and can not be changed in the job menu either. However, a locked job still can be copied
into another job that can be modified.
Flap closer
The flap closer offset is set in the System Settings menu, Flap closer offset. In the Flap closer
menu in the Job Settings menu you can adjust the timing of the activation of the sealing solenoid
(So3) on a per-job basis. You can use this function to improve the sealing process per job. The
timing has influence on the position of the filled envelope with its flap fixed between rollers 21
and 22 prior, before it is transported between the sealing rollers. This position can be adjusted
between -10 and + 10 mm (with respect to the default envelope position).
4.3.3
Service tests
Photocells
This machine uses so-called intelligent photocells. The currents of the photocell transmitters are
adjusted in such a way that the no-paper output voltage of the photocell receiver is within a
certain voltage range of the photocell receiver. In this way, a reasonable amount of dust on the
photocell sensors can be compensated for. The control mechanism ensures that very reliable
paper and no paper decisions are being made, based on the paper photocell condition.
The screens provide real-time information on the various paper photocells. You also can see if
the relevant photocell sees paper.
4-4
rev. 1.0 - 12/2009
Service Manual
075.1
Press the Cal. button to adjust the photocells.
Note: Before readjusting the photocells it is strongly recommended to remove all paper
from the machines and to clean all the sensors (both transmitter and receiver!) of the
photocells.
After the photocell have been adjusted, the percentages in the screens should be lower (if the
cleaning advice was followed). If no paper is present, the photocell output voltage should have
a value between 0.8 V and 1.5 V. A value below this voltage range indicates that the photocell
is too dirty. A value above this voltage range may occur if after readjusting a photocell dust is
removed. In both cases, the photocells must be adjusted.
If the photocell current percentage is below 75%, the message OK is shown. A percentage
between 75% and 99% results in a Clean message. The photocell should be cleaned before
resetting the photocells. The message Defect is shown when the percentage is 99% or 100%
Digital inputs
The digital input screens show:
The status of the three safety switches: MS1 (collator switch), MS2 (front switch) and MS3
(loc switch)
The status is real time: a change is reflected in the displayed status. This allows you to
easily check the correct operation of the three microswitches.
The status of the collator stop sensors: if the sensor is covered (closed) or not (open).
If the water reservoir is present and if the water level is sufficient
The status of the two folder cam disks (SPH3 & PD3; SPH4 and PD4)
You can also test the folder cam discs. During the test the relevant cam disc moves one
half cycle. The cam disc status changes from open to covered or from covered to
open. If you press two times on a test key the cam disc has made a full cycle.
The pulse disc and SPH2 for the main motor M2 (pulse disc central)
You can also test the pulse discs of the motors. Both the speed and the quality (duty cycle)
are tested. Detailed information is obtained via the minimum (Min.) and maximum (Max.)
value. The speed range should be between 75% and 125%. The Distance (Duty cycle)
value should be between 50% and 150%. If this is the case the message 'Good' is displayed.
The speed is checked by measuring the average pulse width and comparing it to the initial
value. When the speed is much lower than the initial value, check the mechanical load. If it
is higher, the pulse disc might be loose.
The Distance (duty cycle) is measured of each pulse and the minimum and maximum values are shown. When a pulse (an indented area) is not detected (for example because of
dust build up) the pulse distance will show a value of Min. 0% and/or Max. 200%.
The pulse discs SPH1 for the collator motor M1 (pulse disc collator)
Actuators tests
From this menu you can select an actuator and activate it. Some tests are only possible with
running motor. With the upper button you can switch the motor off or let it run continuously
during actuator tests.
The following tests are possible:
Main motor (M2): the motor runs as long as the Test button is pressed.
Fingers magnet (So1): the fingers move forward as soon as the Test button is pressed. Only
after releasing the Test button the fingers will move back to their rest position.
Eject roller magnet (So2): press the Test button and keep it pressed: the solenoid is
activated and deactivated after a short time.
Closer magnet (So3): press the Test button and keep it pressed: the solenoid is activated
and deactivated after a short time.
rev. 1.0 - 12/2009
4-5
075.1
Service Manual
Envelope track clutch (CL8): press the Motor ON button and press the Test button. The
envelope track clutch is activated.
Stacker clutch: press the Motor ON button and press the Test button. The stacker clutch is
activated.
Brush magnet (So4): press the Test button and keep it pressed: the solenoid is activated
and deactivated after a short time.
Shunt forward: the collator motor M1 runs and clutch CL4 is activated
Shunt reverse: the collator motor M1 runs and clutch CL5 is activated
Collator run in: the collator motor M1 runs in the direction of the document stop position
Collator run out: the collator motor M1 runs in the direction of the folder
Folder: the collator motor M1 runs and clutch CL4 is activated
Folding table 1: the folding table turns a half fold cycle. If you press the Test button for the
second time the folding table returns to its original position.
Folding table 2: the folding table turns a half fold cycle. If you press the Test button for the
second time the folding table returns to its original position.
Collatorstop to A: both collator stops move up and down
Collatorstop to B: the centre collator stop moves up and down
Collatorstop to C: no collator stop movement
Feeder clutches: the main motor M2 is switched on and the relevant feeder clutch is
activated if the button is pressed.
The maxiFeederTM option is only available if the maxiFeederTM is present. As long as the
button is pressed, its motor will run.
Run in
This screen has a counter (with default value of 500) that shows the number of process cycles
that will be executed, without paper or envelopes present in the machine.
Note: Never execute the run in test with any documents present in the machine. The
timing of the actions for a simulated process cycle are fixed, they are not based on
parameters such as the document length. A run in test with documents present in the
machine would only result in severe paper jamming.
After pressing the Start/Stop key, the run in test will start/stop. The machine stops
automatically if the counter value is zero.
If some covers are removed (but not the safety covers!), you can watch the sequence of the
various mechanical actions, which reflect the sequence of events during normal operation.
4-6
rev. 1.0 - 12/2009
Service Manual
075.1
DFC test
The DFC screen shows the real-time DFC output voltage, expressed in millivolt. For testing the
DFC it is best to start the system with paper underneath the DFC sensor (and covering the feeder
photocell too). This results in starting the adjustment procedure. The voltage should be approx.
4.1 V when a single sheet (80 grams/20 lb) is below the sensor (the voltage of a non-adjusted
DFC, without paper, is approx. 5 V). When this sheet is removed the voltage will drop with
approx. 0.25 V. The voltage drop depends on the thickness/quality of the paper. The table gives
an indication how much the voltage will drop with the relevant paper qualities.
Paper quality
(g/m2)
Voltage drop
(V)
65
0.2
80
0.25
120
0.35
160
0.5
Although the readings are correct it still could be that the DFC is not functioning correctly in
AUTO mode. It is recommended to clean the moving parts of the DFC to make sure that dust or
paper particles are not affecting the DFC functioning.
If you restart the system, the DFC voltage is erased from memory, has no reference and shows
some unexpected value. After a first sheet is passed through the feeder the DFC will be
calibrated at about 3.96 voltage. For the next sheet the DFC is functioning correctly.
During normal operation the system automatically recalibrates. Manual DFC testing and
calibration can be easily done by removing the cover (with an opened loc) and manually turning
the feeder separation gear. In the service menu DFC test menu, the voltage can be verified.
Touch screen
In the Touch screen tests menu you can verify the correct functioning of the touch screen. If you
press Test touch screen, a graphical object will be displayed on the screen at each point where
the screen is touched. The screen can be touched with either a finger or a (non-scratching) pen.
If the area touched does not correspond with the displayed object, the touch screen should be
calibrated. To do this, use the Calibrate touchscr. button and follow the commands on the
screen.
Envelope only mode
If you set the envelop only mode to On, all jobs will only process envelopes. Use this mode for
a service test without documents.
Stop key
For testing purposes it is possible to create a stop key in the user interface (Mode is On). This
stop key appears as soon as the system runs a job. Deactivate this key (Mode is Off) when you
have finished servicing the system.
If you press this extra stop key the system does not stop immediately, but on the first
opportunity while processing. Because of this there can be incomplete sets in some parts of the
system.
4.3.4
Service counters
This menu allows you to read, set, or reset the service counters:
The Since last visit counter can be reset.
rev. 1.0 - 12/2009
4-7
075.1
Service Manual
The Since installation counter is displayed.

The next visit after counter can be incremented in 5000 steps to a maximum value of
6.000.000 steps. A value under 5000 results in the value OFF.
The feeder counters (1 through 3) can be reset to zero.
The envelope hopper counter can be reset to zero.
4.3.5
Reading: OMR
OMR code definition

The OMR code definition menu allows you to define the OMR reading codes. The number of
different menu items depends on the level of OMR, see the table.
Per item choose between Yes and No (toggling function). The line spacing can be changed in
steps of approximately 0,03 millimetre. The Lpi value reflects the number of lines per inch, the
millimetre value is the distance between two successive marks.
The Table summarizes the possibilities of the OMR code.
Note the following:
When some functions are not used, marks will shift up.
The minimum marks in Level 1 are: Start mark + accumulate or insert. That is 2 marks in
total. However, it is highly recommended to add a third mark, the safety mark in the
minimum configuration.
The feeders programmed as selective feeder cannot be used as a reading feeder.
Of the marks 'Insert', 'Divert' or 'Stop' only one should be printed on each single document
to indicate the end of the set. The marks are so called 'mutually exclusive'.
The divert and continue mark cannot be used. The divert and stop mark will make the set
stop in the collating area.
If a level increase occurs, the extra functions will use the default setting (= off). When the
level is decreased the not available functions will be switched off without giving any error
message.
The sequence will be reset after power up; a job change; a successful clear action or an
error message.
When parity is used the parity of the printed marks should be even.
Reading code parameter
Value
Description
Level
Start mark
Yes
Start mark
Basic, Advanced
No
No start mark
Basic, Advanced
Mark
Mark is insert; space is accumulate
Basic, Advanced
Space
Mark is accumulate; space is insert
Basic, Advanced
Yes
Divert mark (implemented as a stop

mark)
Advanced
No
No divert mark
Advanced
Yes
Stop mark
Advanced
No
No stop mark
Advanced
Yes
Selective feed on station 1
Advanced
No
No selective feed on station 1
Advanced
Insert on
Divert mark
Stop mark
Selective feed 1
4-8
rev. 1.0 - 12/2009
Service Manual
075.1
Value
Description
Level
Selective feed 2
Yes
Advanced
No
Advanced
Yes
Advanced
No
Advanced
Yes
Mark is no sealing, space is sealing
Advanced
No
No sealing control
Advanced
No
No sequence check
Advanced
1 (mark)
Sequence check 1 with 1 mark
Advanced
2 (marks)
Sequence check 2 with 2 marks
Advanced
3 (marks)
Advanced
Yes
Parity check, based on a parity mark
Basic, Advanced
No
No parity check
Basic, Advanced
Yes
Safety mark
Basic, Advanced
No
No safety mark
Basic, Advanced
4 10 lpi
Line spacing in increments/

decrements of 1/32" (keys 4 and 5);
Displayed in 2 digits in lpi and mm
Selective feed 3
Sealing control
Sequence check
Parity check
Safety mark
Line spacing
In the OMR code type menu you can choose Legacy. These definitions are meant for the former
PFE code definition as used on the Minimailer 2, 4 and Easy start.
Within the code definition Legacy the following functions are available and can be defined:
Description
Level
Gate mark
Not selectable, always on
Basic, Advanced
Insert on
Not selectable, always on (insert on

mark)
Basic, Advanced
Yes
Parity check, based on a parity mark

(even parity)
Advanced
No
No parity check
Advanced
Yes
Mark is no sealing, space is sealing
Advanced
No
No sealing control
Advanced
Yes
Advanced
No
Advanced
Yes
Advanced
No
Advanced
Parity
Unseal
Selective feed 2
Selective feed 3
rev. 1.0 - 12/2009
Value
4-9
075.1
Service Manual
Value
Description
Level
Selective feed insert
Yes
Advanced
No
Advanced
Yes
Stop mark
Advanced
No
No stop mark
Advanced
Off
No sequence check
Advanced
1 (mark)
Sequence check 1 with 1 mark
Advanced
2 (marks)
Advanced
3 (marks)
Advanced
4 (marks)
Advanced
5 (marks)
Advanced
Line spacing
4 10 lpi
Line spacing in increments/

decrements of 1/32" (keys 4 and 5);
Displayed in 2 digits in lpi and mm
Read direction
Yes
Reading direction is reversed
Advanced
No
Normal reading direction
Advanced
Halt
Sequence check
OMR code test

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

The settings of the current job are used for this test. This implies that an OMR job must be
selected, otherwise the text Select a job with OMR will appear. If the OMR codes on the
paper used differ from the OMR codes for the current job, the number of marks that have
been read are incorrect.
After selecting Adjust, another menu appears. Information about the number of OMR test
sheets to be placed in the upper feeder is first shown.
Select Start adjust to start the OMR adjustment.
The text Adjusting appears. The end result will either be:
- Adjusting OK
- Adjusting FAILED
If readjustment of the OMR electronics was successful, Save and exit is displayed.
Select Save and exit to return to the original OMR menu. This menu now shows the benefit
of readjusting the OMR electronics.
Select the Test key to show:
Mark quality (the quality of the marks: bad, good or very good)
The mark quality is either:
Bad: Mark amplitude < 0.6 V
Good: Mark amplitude between 0.6 V and 1.5 V
Very good: Mark amplitude higher than 1.5 V
Marks (the number of marks that have been read)
Gain (the gain of the amplifiers involved in the OMR electronics, the values are 1, 3, 5 or 7)
Vp-p: peak to peak voltage

Select the OMR info key to display the information screen. This screen shows additional OMRrelated information. This information is based on the last read document and the job settings
(OMR code type etc.). The displayed information is what is interpreted from the read OMR code.
4-10
rev. 1.0 - 12/2009
Service Manual
075.1
Select Show OMR to display a graphical representation of the marks that had been read
(oscilloscope function). The information shown is derived from the most recently read document.
The information screen shows the time-dependant OMR output voltage and the reading window.
See following figure.
The start of the window is represented by a vertical line, the end of the reading window is also
represented by a vertical line. In between the marks should be given where the position of the
marks related to the window position is also giving some information, i.e. when the first mark is
very close to the opening of the window; this could mean that the window position is
programmed wrong.
The upper horizontal dotted line represents the noise level, i.e. the white level. The lower
horizontal dotted line represents the level below which a mark (i.e. detection level) has been
detected. The detection level is determined when the adjustment procedure is performed. The
detection level is 60% of the top level. A mark is detected as an OMR-mark when more than 5
digital samples consecutively are below the detection level.
The numbers 1 through 6 indicate where a mark is expected. The distance between the numbers
is exactly the same as the programmed line spacing. Select the arrows to scroll to the left or the
right. Scrolling to the right shows a later point in time; scrolling to the left shows an earlier
situation.
4.3.6
Reading: BCR
Read config sheet

The button Read config sheet allows you to read Barcode Reading (BCR) settings from a BCR
configuration sheet. Follow the instructions on the screen.
BCR code definition
The BCR Code definition allows you to define the reading codes for barcode reading.
Per item choose between Enabled, Disabled or Ignored.
The table in this section summarize the BCR code options.
Note the following:
You can only select feeder 2 as a reading feeder if Selective feed 2 is set to Ignore.
If a level increase occurs, the extra functions will use the default setting (= off). When the
level is decreased the not available functions will be switched off without giving any error
message.
The sequence will be reset after power up; a job change; a successful clear action or an
error message.
If a functionality is not available on the machine, but printed in barcodes, set this
functionality to Ignore. This offers the possibility to use the same coding throughout
different machine types.
rev. 1.0 - 12/2009
4-11
075.1
Service Manual
The position of a reading functionality depends on the availability of other functions and on the
number of characters you choose for a function. If a functionality is disabled, the other functions
shift upwards.
Note: The code always should start and end with an * (asterisk symbol).
Neopost barcode scheme
Reading code
parameter
Code
length
Default
Description
settinga
Page N of M
M: 0 - 2
N: 0 - 2
D, 0
D, 0
n<m: accumulate
basic
n=m: insert
n>m: invalid, sequence error, divert
The field Chars shows the number of character
positions available for N / M:
1, 2: 1 or 2 character positions
1 S, 2 S: 1 or 2 character positions with N and
M in reverse order (M first, then N)
Sheet Sequence
0-3
E, 3
Sheet counter
If a sheet number is missing, an error is
generated.
advanced
Group Sequence
0-3
D, 0
Set counter
If a set number is missing, an error is
generated
advanced
Insert / Accumulate
1 bitb
Insert and accumulate command
basic
Divert 1
1 bit
Divert and continue

advanced
Divert and stop
(see Divert on page 4-13)
(On 075.1 both will be interpreted as divert to
collator and stop)
Divert 2
1 bit
Not possible on 075.1, 080.1 and 086.1. If

these functions are available in the barcode
set them to Ignore.
advanced
Selective Feeds
1 bit each E
A maximum of 7 feeders (086.1: feeder 7 is

versaFeeder) is available for selective feed
advanced
Do not glue
1 bit
Sealing control: enable or disable sealing

(086.1 only)
advanced
Envelope selection 1 - 3 1 bit each E
Not possible on 075.1, 080.1 and 086.1
advanced
Exit. Sel. 1
Stacker or side exit (086.1 only)
advanced
4-12
1 bit
Level
rev. 1.0 - 12/2009
Service Manual
075.1
Neopost barcode scheme (Continued)

Reading code
parameter
Code
length
Default
Description
settinga
Level
Exit. Sel. 2
1 bit
Present on deck & continue

Present on deck and stop (086.1 only)
advanced
Exit. Sel. 3
1 bit
Not possible on 075.1, 080.1 and 086.1
advanced
Stop
1 bit
Stops the inserter
advanced
Customer ID
0 - 16
D, 0
If customer ID equals the ID on the previous

page: accumulate
If customer ID is different from ID on the
previous page: insert the set
basic
(not possible on 075.1, needs reverse reading)

a.
b.
E is Enabled, D is Disabled
4 bit values represent one barcode character
Divert
In the BCR Code definition menu you will find the following settings that are not mentioned in
the table:
Divert and continue
Divert and Stop
Present on deck and continue
Present on deck and stop

These settings are covered as follows:
Divert & Continue and Divert & Stop are directly linked to the Divert 1 function and the separate
Stop function. This means:
When you enable Divert & Continue, Divert 1 is also enabled automatically.
When you enable Divert & Stop, both Divert 1 and the Stop function are enabled
automatically.
In both cases do not change the settings of the Divert 1 and the Stop function, because this will
change the setting of the Divert & Continue and Divert & Stop function.
Note: The reason for this behavior is to have different DS systems support the coding
scheme.
rev. 1.0 - 12/2009
4-13
075.1
Service Manual
BCR code test

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

The settings of the current job are used for this test. This implies that a BCR job must be
selected, otherwise the text Select a job with BCR will appear.
After pressing Adjust, another menu appears. Information about the number of BCR test
sheets to be placed in the upper feeder is first shown.
Press Start adjust to start the BCR adjustment.
The text Adjusting appears. The end result will be either:
- Adjusting OK or
- Adjusting FAILED
If readjustment of the BCR electronics was successful, Save and exit is displayed.
Press Save and exit to return to the original BCR Test menu.
When testing the reading head the displayed test information is:
Barcode quality (the quality of the marks: bad, good or very good)
The quality is either:
- Bad: Mark amplitude < 0.6 V
- Good: Mark amplitude between 0.6 V and 1.5 V
- Very good: Mark amplitude higher than 1.5 V
Vp-p: peak to peak voltage

Press Show BCR to display a graphical representation of the barcode that has been read
(oscilloscope function). The information shown is derived from the most recently read document.
4.3.7
Diagnostics
Start test
This test checks if all motors, clutches and sensors are correctly connected. The system test
derives the status of the actuators and clutches by briefly activating the actuators and then
measuring the current.
Error counters
In the Error counters menu a list is given of the top 40 occurred errors. The errors are sorted
based on quantity. That means that the errors occurring most frequent are in the top of the list.
Press clear to clear all error messages.
Last error list
This menu displays the last 50 errors that occurred. Besides the error code also the job number
and the corresponding counter value are given.
Press clear to clear all error messages.
4.3.8
Online service
Server settings
Use this menu to enter:
the IP address of the server
the server port of the server

Reset CB data
Use this menu to clear the data on the communication board, and to reset the status of the
communication board to undeclared.
4-14
rev. 1.0 - 12/2009
Service Manual
075.1
Once the communication board has been reset, it can be used in another system. As soon as the
communication board is installed in another system (i.e. during a board replacement), it will be
automatically reset.
Test CB
Select Test CB to check the following:
the serial port

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

The system checks if:
the communications board has a battery, and the battery is working correctly.
the communications board clock is working correctly.
Fail or Pass will be displayed for each item depending on the result of the test.
4.3.9
Remove blockage
During system start-up, the serial number stored on the main board is compared to the original
serial number in the ID-tag. After a main board or ID-tag has been replaced, the machine may
have lost it's identity, backup counter, and enabled features. This will block the normal operation
of the machine.
The machine will show error INS-SYS-102 (serial number mismatch) during machine start-up.
The user can still access all menus, but the machine will be blocked from running jobs or loadn
Go.The blockage can only be removed if a service technician accesses the password protected
service menu and confirms that the ID-tag or main board has been replaced.
To do this: from the Main menu select Job menu (and enter the PIN code), and then select
Remove blockage.
Main board replacement
After a main board replacement, No will be answered. The identity, backup counter and enabled
features will be restored from the ID-tag.
ID tag replacement
After an ID-tag replacement (factory prepared), Yes will be answered. As a second question, you
will be asked to enter the new total counter of this inserter. A backup of this counter will be
copied to the new ID-tag.
4.3.10 Sealing on franking machine
This option is only available if insertn Frank is set to level 2 or 3. By default, sealing is disabled
on the franking machine when an insertn Frank job is selected. This service menu option,
allows you to ignore the sealing settings of the franking machine.
rev. 1.0 - 12/2009
4-15
075.1
4-16
Service Manual
rev. 1.0 - 12/2009
Service Manual
5
The 075.1
5.1
Transport, storage and installation
5.1.1
075.1
Transport
The system, including all accessories, is transported in one box. The box is attached onto a
pallet. Handle the package with care.
Warning
Do not turn the box on its side.
Prevent the box from falling over.
Prevent the box from shaking.

Note
When shaking (during transport) is expected, follow this procedure:
1. Remove the feed hoppers.
2. Tighten the feeders.
3. Secure the collator.
5.1.2
Unpacking, installation and storage
Before you start

1.
Verify that the system is suitable for the local mains voltage. Refer to the type plate.
2.
The power connection must be easily accessible. Place the system near a socket outlet with protective earth
connection.
Warning
The earth connection is essential for safety.
Unpacking instructions
1.
Remove the two blocks packaging material on top of the system.
2.
Verify that the following parts are available in the box:

-
inserter system (A)
a box with document feeders (E)
a box with one catch tray and one slide (B)1
a power lead (C)
a bag with three spare moistening brushes and a spare moistening cloth
(D)
optional accessories (maxiFeeder, side exit)
B
D
1. If the high capacity vertical stacker is part of the delivery, the catch tray and slide are not contained in the box.
rev. 1.0 - 12/2009
5-1
075.1
Service Manual
3.
Remove the box from the tray.
4.
Remove the blocks on both sides.
5.
Lift the system and place it for example on the optional furniture.
6.
Remove the packaging materials from the following places:

-
Cardboard below the loc, at the document insert position (A)
The foam blocks at the feeders (C)
Fixing pin from the top of the feeder tower (B)
Band and foam block at collator (D)
Note
Do not connect to mains yet.
In case of a high capacity feeder:

-
Cut both wire straps at the high capacity feeder (E).
Remove the transportation plate (F).
C
D
5-2
rev. 1.0 - 12/2009
Service Manual
075.1
Install feeders
Note
If a special feeder is available always install it on the lowest position.
1.
Hold the tray slightly inclined as shown in the figure.
2.
Place the front end of the tray underneath the two black rollers.
3.
Lift the tray (lifting the black rollers) until it is possible to hook the tray into
place.
Install slide and envelope catch tray

Note
The slide and catch tray are not delivered if the high capacity vertical stacker is
delivered.
1.
Attach the slide.
2.
Position the envelope catch tray into the holes underneath the envelope
hopper as shown in the figure.
3.
The distance A should be approximately 1.5 x the envelope height.
A
Install maxiFeeder (option)
1.
Install the maxiFeeder in the same way as the normal feeders.
2.
Connect the connector A to the socket B.
rev. 1.0 - 12/2009
5-3
075.1
Service Manual
Install high capacity feeder tray (option)

1.
Pull down lever A.
2.
Hook in the feeder tray.
3.
Release lever A.
A B C D E
Install high capacity vertical stacker (option)

1.
Hook in the vertical stacker.
2.
Connect the connector.
A B
Install side exit and catch tray (option)
1.
Remove the envelope catch tray and the slide.
2.
Hook in the side exit.
3.
Mount the new catch tray.
Fill the reservoir

1.
2.
Fill the reservoir B up to lip C with sealing liquid.
3.
Open the front cover A.

Close the front cover A.
5-4
rev. 1.0 - 12/2009
Service Manual
075.1
Connect the system to the mains power supply

Set language
1.
Switch on the system.
2.
Select the language for the display.
3.
Press No if the software asks if you want to select the language every time the system is switched on.
Online Services (option)

1.
Go to Supervisor menu, Online services, Configuration and enter:

-
Prefix if applicable
Date (in second configuration window)
Time (in second configuration window)
2.
Press the OK button.
3.
Press Connection, Connect for the initial declaration call.
4.
Press the i button to follow the status of the connection.
5.
The initial declaration call is finished if the System status shows "Pending declaration".
6.
Press Connect again for declaration.
7.
Press the i button to follow the status of the connection.
8.
The declaration call is finished if the System status shows "Declared".
Test the system

1.
Load document feeder trays.
2.
Load the envelope hopper.
3.
From the Home menu press New Job, Automatic.
4.
Press the 1x button. If necessary adjust address position, insert position and
insert fingers.
5.
Select a job and write down its fold settings.
6.
Press the 1x button.
7.
Verify that the folds are in the correct position. If not correct, adjust it
(service menu, system settings, Folder offset).
8.
Verify the flap closer quality. If not correct, adjust it (service menu, System settings, Flap closer offset).
Define jobs
Define any jobs according to the customers wishes / applications.
Storage
The system needs to be stored under the following conditions:
Storage temperature:
10 to 40 C (50 to 104 F)
Humidity:
30 to 80%
rev. 1.0 - 12/2009
5-5
075.1
Service Manual
5.2
Mechanical description
5.2.1
General
Warning
Disconnect the mains supply before performing any maintenance.
Warning
The covers and microswitches are fitted for your protection. Do not operate the
machine with any cover removed and with a microswitch cheated, or a hazard to
health will exist.
Throughout this manual the terms left and right-hand side and front and rear side of the machine
are used. These are made with the machine viewed from the input (document feed) side of the
machine.
5-6
rev. 1.0 - 12/2009
Service Manual
5.2.2
075.1
(Dis)assembly - Covers and plates
Right-hand side cover
RH
LH
To disassemble the right-hand side cover:
1
2
3
Open the upper unit by lifting the hand grip (2).

Remove (loosen) the five screws of the right-hand side cover (1).
To remove the cover, turn and move as shown in the figure.
rev. 1.0 - 12/2009
5-7
075.1
Service Manual
Left-hand side cover
RH
LH
To open the left-hand side:

1
2
3
Open the upper unit (1) and the hinged cover (4).
Remove (loosen) the two screws of the left-hand side cover (2).
Remove the two screws and loosen one screw of the inner cover (3).
5-8
rev. 1.0 - 12/2009
Service Manual
075.1
Top cover feeders, covers collator area, power supply cover
RH
LH
1
2
3
4
Remove the top cover feeders (1), the covers of the collator area (2), and the power supply
cover (3).
Remove the water tray.
Place the machine carefully at the right hand side on a felt path.
Slacken the three screws of the bottom plate (4) and remove the bottom plate.
rev. 1.0 - 12/2009
5-9
075.1
Service Manual
Covers upper unit
2
3
RH
4
LH
To easily access the interior, open the covers in the following order:
1
2
3
Vertical transport cover (4)

Top covers (1, 2, and 3)
Loc cover (5)
5-10
rev. 1.0 - 12/2009
Service Manual
5.2.3
075.1
(Dis)assembly - Electrical components
Note
When a board is installed and the system is switched on, you must check if the correct software
is installed. If the correct software is installed, the machine will start to synchronize with the
ID-tag (2994504Z). See Section 3.5.4 The ID-tag. If the board is new to the system, the
error message INS-SYS-501 will be displayed, which indicates that the serial number in the IDtag (2994504Z) does not match the serial number in the FRAM of the main board. This will
prevent the machine from working. Before you can use the system, you will have to remove
the blockage. See Section 4.3.9 Remove blockage.
Warning
Potential hazard may exist to electronic hardware in conditions with static
electricity. It is advised that, when handling electronic parts, an earth connected
wrist band is used in order to be permanently discharged from static electricity.
Main board
LH
To disassemble the main board:

1
2
3
4
Disconnect the wiring to the main board (1).

Remove the screw (2).
Lock washer and spacer.
Carefully pull the main board from the board holders as shown.
rev. 1.0 - 12/2009
5-11
075.1
Service Manual
ID-Tag
Ordering and installing new ID-tag:
When the ID tag fails, the system can continue running without using OMR or insertn
Frank features. At start up, and at each 100 cycles, the operator will see an error message
ID/Option memory update fails or ID memory not detected.
Place an order for a new ID-tag for a specific serial number.
NTBV will send you a replacement ID-tag containing the same features as known by NTBV
for that serial number.
As the old ID-tag may contain valuable features, double check the provided features with
your own administration.
When correct, make sure you destroy the old ID-tag (ID-tags may never be used on other
systems!).
At the installation of the new ID-tag, the system will go into blockage. In the service menu
you can de-block the system and set the counter.
Display board
1
4
LH
Before removing the display (2) or the display board (3), the complete display bracket must be
removed from the system.
1
2
3
4
5
6
Remove the top cover (1).

Remove the two screws that hold the bracket to the system.
Disconnect the main cable display (4).
Withdraw the display bracket carefully.
Disconnect the wiring (5 and 6) so that the display board can be removed.
Carefully remove the display board.
5-12
rev. 1.0 - 12/2009
Service Manual
075.1
LH
To remove the display:

1
2
Remove the four screws (3) which secure the display (2) to the mounting bracket display
(6).
Withdraw the display (2) carefully.
Note
Connect the wiring before replacing the display. Be sure to replace the four spacers (5).
rev. 1.0 - 12/2009
5-13
075.1
5.2.4
Service Manual
(Dis)assembly - Feeder modules and vertical transport right-hand
The feeders, the vertical transport and the fold unit are driven by belt (4) and the accompanying
pulleys, gears, etcetera as shown in the following figure.
When the machine is running the four transportation axles are continuously driven by the belts
(4, 5 and 6). The three upper transportation axles are equipped with a clutch and a pulley.
When, for example, the clutch (2) is activated, the accompanying feeder is driven by pulley (3)
and belt (1) and a document is fed to the vertical transport track.
1
2
5
3
4
RH
5-14
rev. 1.0 - 12/2009
Service Manual
075.1
Drive mechanism right-hand - Belts and pulleys
2
3
4
RH
Belt 4
1
2
3
Slacken the two screws of the belt tensioner (5).

Shift the belt tensioner downwards.
Remove belt 4 from the pulleys.
Pulley 1
1
2
3
Loosen the main belt, PJ belt and drive belt inserter.

Remove the spring clip.
Slide the main pulley of the axle.
Pulleys 2 and 3
Pulleys 2 and 3 are snapped to their cyl. pins. They can be removed by pulling them of the axle.
rev. 1.0 - 12/2009
5-15
075.1
Service Manual
12 13 14
RH
Belt 4
1
2
Slacken the hexagonal head screw of the belt tensioner (1).

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

Withdraw the tensioner.
Slide the pulley 5 from the axle.
Remove the cyl. pins from the axle.
Slide pulley 8 of the axle.
5-16
rev. 1.0 - 12/2009
Service Manual
075.1
Drive mechanism left-hand
6 5 4 3
LH
Belt
1
2
Unhook the tension spring (2) from the inside frame.

Remove belt 1 from pulley 3.
Clutch and Pulley

1
2
3
Disconnect the wiring of the clutch.

Remove the spring clip (6).
Slide the clutch (5), the disc (4), and the pulley (3) of the axle.
rev. 1.0 - 12/2009
5-17
075.1
Service Manual
Drive mechanism left-hand high capacity feeder
Belts
1
2
3
4
Remove
Remove
Remove
Remove
nut (1) and the spring clips that hold plates (2) and (3).
the plates.
belts 4, 5, and 6.
the pulleys if necessary.
Clutch and Pulley (7)

1
2

Remove the spring clip and slide the clutch (8) and pulley (7) from the axle.
5-18
rev. 1.0 - 12/2009
Service Manual
5.2.5
075.1
(Dis)assembly - Feeders
All the feeders are provided with dividable drive axles. Removal of the complete feeders:
1
2
3
Remove the hoppers.

Remove the extension part of the drive axle (7, refer to the following figure). Take care that
it is a left side screw-threaded axle end. Each feeder can now be removed separately.
Fix the main axle by a pin on one of the holes.
At the right-hand side the feeders are equipped with a tension spring for proper lifting of the
feeder. The tension spring is hooked on a mounting bracket at the frame.
Note
Do not remove the mounting bracket or exchange the tension spring from one to another
feeder. Each spring is specially adjusted from the factory by positioning the mounting bracket.
If you remove the spring, first mark the hole it is attached to.
Top feeder (feeder 3)
7
8
LH
1 2 3 4 5 6
9 10 11
RH
To loosen the top feeder:

1
2
3
4
5
6
7
8
9
10
Unhook the tension spring (10, see note above) from the screw (9) (on the right-hand side
of the feeder).
Disconnect the wiring of the feeder.
Cut the wire straps.
Remove the wiring from the left-hand inside frame.
Remove the spring clip (6), clutch (5), belt (3), and pulley (4) from the top transportation
axle.
Remove axle part (7) of the lower transportation axle.
Remove the top transportation axle (11) by moving it in the right-hand direction.
Remove the screw of the left-hand and right-hand hinge pin (2) of the top feeder.
Remove axle 1 out of the lock.
rev. 1.0 - 12/2009
5-19
075.1
Service Manual
RH
LH
A
To remove the feeder:
1
2
3
Move the feeder a bit downstream as indicated (A).

Lift the right-hand side of the feeder first.
Remove the feeder from the machine (B).
Note
Be careful when replacing feeder 3, the hinge pin at the right-hand side is locking the ball
bearing.
5-20
rev. 1.0 - 12/2009
Service Manual
075.1
High Capacity Feeder
RH
LH
1 2 3
4 5
To loosen the High Capacity Feeder:

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

Unhook the large tension spring on the LH side of the feeder.
Note
Keep the springs separated. They are not interchangeable.
3
4

rev. 1.0 - 12/2009
5-21
075.1
5
6
7
8
9
10
Service Manual

Unscrew the drive axle extension (5, LH side). It is left hand threaded.
Remove bushes (2) on both sides from the feeder module.
Remove the plastic clips from the bearing (3) (see detail B).
Hold the feeder module and shift the ball bearings (3) to the inside, out of the side frames
(see detail C).
Lift the axle and remove the feeder in the direction of the big arrow.
Note
In case tension spring (1) is replaced or you do not remember the hook it was attached to: the
normal force of the separation roller with an empty feeder should be between 1.7 N and 2.5 N.
Middle feeder (feeder 2)
7
6
5
LH
1 2 3 4
8 9 10
RH
To loosen the middle feeder:

1
2
3
4
5
6
7
8
9
10
11
Unhook the tension spring (9, see the note on tension springs in Section 5.2.5
(Dis)assembly - Feeders) from the screw (8) (on the right-hand side of the feeder).
Remove the spring clip, clutch (4), belt, and pulley of the middle transportation axle.
Remove axle (10) to the right-hand side.
Remove sprocket (7).
Remove the guide plate (1).
Remove the screw of the left-hand and right-hand side hinge pin (2) of the middle feeder.
5-22
rev. 1.0 - 12/2009
Service Manual
075.1
RH
LH
To remove the middle feeder:

1
2
Move the feeder a bit downstream (A).

Remove the feeder by turning it out of the machine as indicated (B).
Note
Be careful when replacing feeder 2, the hinge pin at the RH side is locking the ball bearing.
Lower feeder (feeder 1)
6
5
LH
1 2 3 4
7 8 9
RH
To loosen the lower feeder:

1
2
Unhook the tension spring (8, see the note on tension springs in Section 5.2.5
(Dis)assembly - Feeders) from the screw (7) (on the right-hand side of the feeder).
rev. 1.0 - 12/2009
5-23
075.1
3
4
5
6
7
8
9
10
Service Manual

Remove the spring clip, clutch (4), belt (3).
Remove axle (9) to the right-hand side.
Remove the guide plate (1).
Remove the two screws of the left-hand and right-hand side hinge pin (2) of the lower
feeder.
To remove the lower feeder:

1
2
Move the feeder as far as possible downstream (A).

Remove the feeder by turning it out of the machine as indicated (B).
RH
LH
Note
Be careful when replacing feeder 1, the hinge pin at the RH side is locking the ball bearing.
5-24
rev. 1.0 - 12/2009
Service Manual
075.1
Automatic separation feeder (with daily mail)

This section describes the replacement of the rollers and pulleys of the feeder. For several
replacements it is necessary to remove some covers above or below the feeders. The removal
of these covers is shown in the following figure.
1
2
3
4
5
6
LH
RH
To remove cover 1 to 4:
1
2
3
4
5
6
Remove the screws on the right-hand side. To remove cover 1, its necessary to remove the
top cover first (see Section Top cover feeders, covers collator area, power supply cover
on page 5-9).
Pull cover 1, 2 and 3 backwards on the right-hand side and pull it out on the left-hand side.
Loosen the screws (6) at cover 5.
Remove the cover.
Pull cover 4 backwards on the right-hand side.
Pull it out on the left-hand side.
rev. 1.0 - 12/2009
5-25
075.1
Service Manual
Rubber paper pullers
RH
LH
1 2 3 4 5
Note
In case of the high capacity feeder remove the cover plate from the feeder module to get
access to the feed axle assy.
To remove the rubber paper pullers (all feeder types):
1
2
3
4
5
6
Remove bracket (5) from the right-hand side of the feeder module.
Remove the feed axle assy. (2) in the right-hand side direction (A) until the left-hand side
is clear from the axle (1).
Tilt the axle assy. (2) at the left-hand side (B) and withdraw the right-hand side of the axle
from the hole in the feeder frame.
Remove the axle assy. as indicated (C).
Hold the plastic cover (3) in place with one hand and push firmly against the rubber paper
puller as indicated (D).
Rotate the axle 180 degrees and push again. Repeat the rotating and pushing until the
paper puller can be pulled of the axle.
Note
Ensure on replacement that the plastic cover is replaced below the ridge (3) on the paper guide
and that the feeder assy. is correctly fitted onto the axle. Ensure that the belt runs across the
pulleys.
5-26
rev. 1.0 - 12/2009
Service Manual
075.1
Pulley of paper puller axle
RH
LH
To remove the pulley from the paper puller axle:

1
2
Remove the feed axle assy. as described in Section Rubber paper pullers.
Release the assy. (1) from the plastic cover and remove it.
Upper separation roller

Note
The feeder unit does not need to be removed for replacing separation rollers.
Grease
RH
Push
LH
2
To remove the upper separation roller:
1
2
3
4
5
6
7
Remove the feed axle assy. as described in Section Rubber paper pullers on page 5-26.
Click the plastic cover (2) off the axle (A).
Remove it with the belt and the paper pulleys from the feed axle.
Remove the grease from the left hand side of the feed axle with some alcohol.
Push the feed roller (1) to the left hand side of the axle as indicated.
Rotate the axle 180 degrees and push again.
Repeat the rotating and pushing until the feed roller can be pulled of the axle.
rev. 1.0 - 12/2009
5-27
075.1
Service Manual
Note
Before replacing the feed roller, ensure that the axle is free of grease. After replacing the feed
roller, put some grease Molykote PG 65 on the plastic cover (2) as shown in the previous
figure. Replace the plastic cover with the belt and the rollers.
Lower separation roller
Note
The feeder unit does not need to be removed for replacing separation rollers. In case of a high
capacity feeder remove the front plate to get access to the lower separation roller. To remove
this front plate, loosen (but not remove) the screw that holds the plate.
When you replace the plate, the daily mail switch should point to auto, not to daily mail.
RH
LH
To remove the lower separation roller:
1
2
3
4
Remove cover 3 as described in Section Automatic separation feeder (with daily mail) on
page 5-25.
Remove bracket (3) from the right-hand side of the feeder module.
Move the separator axle assy. (2) in the right-hand side direction (A) until the left-hand side
is clear from the hinge plate (1).
Move the axle assy. (2) downwards side and withdraw the right-hand side of the axle from
the hole in the feeder frame.
5-28
rev. 1.0 - 12/2009
Service Manual
075.1
Slide the roller (1) of the axle assy. (2) as shown in the following figure.
RH
LH
Note
Before replacing the feed roller, ensure that the axle is free of grease.
Gears
For the removal of the gears at the left-hand side of the feeder it is not necessary to remove the
feeder from the machine.
The gear 48T can be removed after the extension axle with the pulley etc. has been removed.
1
2
3
Remove the spring clip securing the gear 64T.

Lift the feeder.
Slide the gear 64T of the axle.
rev. 1.0 - 12/2009
5-29
075.1
5.2.6
Service Manual
(Dis)assembly - Vertical transport
To get access to several parts of the vertical transport track, remove the vertical transport cover
as described in Section Covers upper unit on page 5-10.
5-30
rev. 1.0 - 12/2009
Service Manual
5.2.7
075.1
(Dis)assembly - Collating area
LH
The parts which are described in this section are located in the upper arm of the collating area.
It is recommended to remove the complete collating arm.
1
2
3
Remove the collator area covers as described in Section Top cover feeders, covers collator
area, power supply cover on page 5-9.
Disconnect the wiring of the collator motor.
Loosen the set screw (6) on the bush (7) as shown in the following figure.
LH
4
5
Pull the motor outside the frame.

Support the collating arm.
rev. 1.0 - 12/2009
5-31
075.1
6
7
Service Manual
Remove the screws (1) as shown in the previous figure (two at the left-hand side and two
at the right-hand side).
Carefully remove the collating arm.
Collator stops
RH
LH
To remove the collator stop motor:

1
2
3
4
5
Remove the plate with clips attached (1).

Remove the moving arm (2).
Remove the gear wheel (3).
Disconnect the collator stop motor wiring.
Remove the two screws (4) that hold the collator stop motor in place, and carefully remove
the motor (5).
5-32
rev. 1.0 - 12/2009
Service Manual
075.1
Belts
8
10
RH
7 6
LH
Transportation belts
The transportation belts are only available as a set. If a belt is worn, all the belts should be
replaced.
1
2
3
4
5
Remove roller (1) from the axle.

Slide the axle to the left-hand side out of the bearings. Take care of the tensioner (2), it is
spring loaded.
Remove the tensioner (2).
Remove the plate (3).
Remove the axles (4 and 5).
The middle transportation belt can now be replaced.

Guide rollers
The guide rollers (8 and 10) are spring loaded.
1
2
3
4
5
6
Remove the accompanying spring clips and washers.

Slide the guide rollers of the axles.
Remove the screw of the axle of the guide roller (9).
Slide the axle to the left-hand side.
Remove the spring clip at the right-hand side of the guide roller.
Slide the roller of the axle.
rev. 1.0 - 12/2009
5-33
075.1
5.2.8
Service Manual
(Dis)assembly - Folder
Right-hand drive mechanism

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

Remove the accompanying spring clip.
Remove the clamping ring.
Slide pulley 2 and 3 of the axles.
5-34
rev. 1.0 - 12/2009
Service Manual
075.1
Gears:
The gears, number 4 (picture on page 5-34) and number 1 (following picture), can easily be slid
of the axles. Take care of the cyl. pins when removing the gears.
RH
rev. 1.0 - 12/2009
5-35
075.1
Service Manual
Upper folder section
RH
1
2
5
8
Belts:
1
2
Slacken the two screws (2) of the belt tensioner (1).

Remove the belt (4) from the pulleys (3 and 5).
Pulleys:
1
2
3
4
Remove the belt (4) as described in the previous section.

Remove the spring clip and the bush of the pulley (3).
Slide the pulley (3) of the axle.
Gears 6 and 8:
1
2
Remove the spring clip, clamping ring and washers.

Remove the gears (6 and 8). When removing gear 6, take care of the cyl. pin.
Gear 7:
1
2
3
Remove the belt (4).

Remove the pulley (5).
Remove gear (7).
5-36
rev. 1.0 - 12/2009
Service Manual
075.1
Left-hand drive mechanism

Gears
LH
5
To remove the gears of the lower folder section (1 to 5) at the left-hand side of the machine:
1
2
3
Remove the circuit board.

Remove the spring clips, clamping rings and washers. Take care of the cyl. pin of the gears
1, 3 and 5 and the spacers of the gears 2 and 4.
Remove the gears (1 to 5).
rev. 1.0 - 12/2009
5-37
075.1
Service Manual
Fold mechanism
12
4 5
RH
10
11
12
13
14
17
16
15
The fold plates (1 and 5) are driven via the curved gears (7, four in total) and two gears (3),
activated by the two clutches (2) on the drive axle (4).
Gears 32T, drive axle
1
2
3
4
Remove the belt (13), pulleys (12 and 14) and freewheel clutch (11).
Remove the locking plate (10) securing the bearing of the drive axle (4).
Carefully move the axle (4) to the right-hand side until the bearing clears the frame.
Carefully lift the axle assembly as far upwards as possible. Take care of the wiring of the
clutches on the axle and the plastic bearing on the left-hand side.
5-38
rev. 1.0 - 12/2009
Service Manual
LH
5
6
075.1
RH
Remove the bearing, spacer, washers and the spring clip of the left-hand side of the drive
axle assembly.
Slide the gear (1) of the axle.
To remove the gear (4) and clutches (2 and 3):

1
2
3
4
5
Cut the wire straps at the connectors of the clutches.

Slide the clutch (2) to the left-hand side of the axle. Take care of the cyl. pin of the clutch.
Remove all the components between the clutches, including the cyl. pin of the clutch (3).
Slide the clutch (3) to the left-hand side of the axle.
Remove the gear (4) from the drive axle.
Note
Ensure on replacement to secure the wiring of the clutches again and that both clutches are
retained by the locking plate. Also ensure that the clutches clockwise and counterclockwise are
placed in the proper position.
rev. 1.0 - 12/2009
5-39
075.1
Service Manual
Curved folder gears

1
2
3
Remove the drive axle assembly as described in Section Gears 32T, drive axle on page 538 (refer to the picture on the same page).
Remove the bearings (9) from the axles (6).
Remove the brake discs (15, spring loaded), the springs, the brake strip (16) and the
bearings (17) from the axles (8).
7 8
1 2 3 4 5 6
22 21 20
LH
12 11 10 9
19 18 17 16 15 14 13
4
5
6
7
8
9
10
Remove the levers for the flap actuators, the bearings, etc. (1 up to 6) from the axles (12).
Pin 6 has to be loosened by a set screw, to be accessed at axle end (12).
Remove the brackets (7) with the sensors.
Remove the brake discs with the bearings (20 up to 22) from the axles (13).
Remove the screws at the left and right-hand side of the guide plate (9)
Unhook the guide plate and remove it.
Remove the screws at the left and right-hand side by which the brackets (10) are mounted
to the upper frames.
Carefully lift each complete fold assembly upwards and withdraw it.
5-40
rev. 1.0 - 12/2009
Service Manual
075.1
First curved folder gears
RH
3
4 5
LH
7
6
9 10
RH
11 12
13 14 15
LH
17
16
To remove the curved gears:

1
2
3
Remove the two screws (6).

Slide both hinge plates (5 and 7) together with the fold plate (4) of the axle.
Pull the curved gears (2 and 8) of the axle.
rev. 1.0 - 12/2009
5-41
075.1
Service Manual
Second curved folder gears

Refer to the figure on page 5-41.
1
2
Remove the hinge plates (15 and 17) in the same way as described previously.
Pull the curved gears (9 and 10) of the axle.
Note
Ensure on replacement that the curved gears and the curved discs are replaced correctly onto
the axle (refer to the following figure). Secure the wiring of the clutches again. The right hand
curved gear is marked with an R and the left-hand curved gear is marked with an L.
Wrong
curved disc
curved gear
spring lever
Right
Note
After replacing and securing the complete fold assembly, check the adjustment of the paper
guides (3 and 11, refer to the figure on page 5-41). See Section Paper guide on page 5-93.
5-42
rev. 1.0 - 12/2009
Service Manual
075.1
Rollers
Input rollers
Remove the drive belt as described in Section Drive mechanism right-hand - Belts and pulleys
on page 5-15.
LH
1
2
RH
3
To remove the input rollers:
1
2
Remove the pulley, the gears of the upper input rollers (1) and the gears of the lower input
rollers (2) as described in Section Right-hand drive mechanism on page 5-34.
Remove the bearing locking plate (3).
rev. 1.0 - 12/2009
5-43
075.1
Service Manual
2 3
RH
6
7
LH
3
4
5
6
7
8
9
Remove the gear 7 of the lower input roller (6).

Remove the bearing locking plate (5).
Remove the guide strip (4) and the guide bracket below it.
Move the upper input roller (2) to the right-hand side until the left-hand bearing is free of
the left-hand inside frame.
Lift the left-hand side of the roller upwards and withdraw the roller out of the right-hand
inside frame.
Move the lower input roller (6) to the right-hand side until the left-hand bearing is free of
the left-hand inside frame.
inside frame.
5-44
rev. 1.0 - 12/2009
Service Manual
075.1
Lower fold rollers

1
Remove the gears (8, refer to the previous figure).
40
"
2
3
4
5
6
7
Loosen the two hexagonal head screws (3).

Push down the solenoid (4) to get access to the screw (2).
Remove the screws (2).
Remove the bearing plate (1).
Move the roller to the right-hand side until the left-hand bearing is free of the left-hand
inside frame.
inside frame.
Note
After replacing the lower fold rollers, check the adjustment of the solenoid. See Section
Solenoids on page 5-94.
rev. 1.0 - 12/2009
5-45
075.1
Service Manual
Upper fold rollers
RH
"
LH
To remove the upper fold rollers:

1
2
3
4
5
Remove the belt with the pulley (5) and the three gears (4) at the right-hand side.
Remove the guide strip (2). This is necessary for the removal of the first fold roller.
Remove the bearing locking plates (3) on both sides.
Move roller 1 to the right-hand side until the left-hand bearing is free of the left-hand frame.
Move the left-hand side of the roller downwards and withdraw the roller out of the righthand frame.
Note
For belt adjustments, see Section Drive belt upper folder section. page 5-92.
5-46
rev. 1.0 - 12/2009
Service Manual
5.2.9
075.1
(Dis)assembly - Main drive mechanism inserter
RH
8
76
The main motor 8 provides the mechanical power to the 075.1, with exception of the collating
area and the collator stops.
Belts
PJ-belt
For removal of the PJ-belt (2):
1
2
3
Disassemble the main drive belt for the feeder and folder section. See Section Drive
mechanism right-hand - Belts and pulleys on page 5-15.
Loosen the two hexagonal head screws (4) of the tensioner (5).
Remove the belt (2) from the main pulley (1) and the motor pulley (3).
rev. 1.0 - 12/2009
5-47
075.1
Service Manual
Drive belt inserter
12
RH
14
13 12 11
10
All moving components of the inserter part are driven by belt 10. To remove belt 10:
1
2
Loosen the two hexagonal head screws of the tensioner (1).

Remove the belt from the pulleys.
5-48
rev. 1.0 - 12/2009
Service Manual
075.1
Belt envelope feed
"
&
'

40

!
"
' & %
$ #
To remove the belt envelope feed:

1
2
Remove the support plate (11) by which the intermediate axle (13) is supported. Take care
of the bearings and the washers.
Remove the belt (5) from the pulley on the intermediate axle and from the pulley on the
envelope feed axle (3).
Pulleys
Pulleys 5 and 9
1
2
Remove the spring clips of the pulleys (5 and 9).

Remove the pulleys (5 and 9).
Pulley 11
1
2
Remove the main pulley (Refer to Section Drive mechanism right-hand - Belts and pulleys
on page 5-15).
rev. 1.0 - 12/2009
5-49
075.1
Service Manual
Pulley 8
1
2
3
Remove the mounting plate (6) with the adjustment plate and the pulse disc sensor.
Remove the pulse disc (7).
Slide the pulley (8) of the axle. Take care of the spacer.
Note
After replacement of the pulse disc sensor be sure that it clears the pulse disc on both sides.
Pulley 9
1
2
3
Remove the belt (5) as described in Belt envelope feed on page 5-49.
Remove the accompanying spring clip and washer from the pulley (9).
Slide the pulley (9) of the envelope feed axle (3).
Pulley 14
1
2
3
Remove the bearings, washers and gears from the intermediate axle (13).
Tap the tension pin from the intermediate axle.
Gears
Gears 3 (sealing rollers)
1
2
3

Remove the spring clips and washers.
Slide the gears (3) of the axles.
Gear 2
The gear (2) is mounted to the axle by a tension pin. To remove the gear (2):
1
2
3
4
5
6
Remove the tension springs of the bearings of the axle.

Remove the spring clip with washer and bearing at the left-hand side of the axle.
Slide the two rollers to the right-hand side.
Remove the cyl. pin from the axle.
Slide the axle with the gear (2) to the right-hand side out of the right-hand inside frame.
Tap the tension pin to remove the gear (2).
Gear 4
The gear (4) is mounted to the pulse disc axle (14) by a tension pin. To remove the gear (4):
1
2
3
4
5
6
7
Remove the pulse disc (7) and the pulley (8).

Remove the spring clip at the left-hand side of the axle.
Slacken the set screws of the two rollers.
Remove the locking plate (13).
Slide the pulse disc axle (14) to the right-hand side out of the right-hand inside frame. While
doing this: remove the bearing, the washer, and the two rollers.
Tap the tension pin.
Dissemble the gear.
Gear 12
1
2
Remove pulley (9).

5-50
rev. 1.0 - 12/2009
Service Manual
075.1

Gears 8, 10, 15, 16, 18, 20 and 22
1
2
Remove the spring clips and washers.

Remove the gears (8, 10, 15, 16, 18, 20 and 22).
Gear 21
1
2
3
Remove the nuts. Take care of the tension spring.

Slide all the parts of the brake rod.
Remove the gear (21).
For adjustment of the friction brake, see Section Friction brake on page 5-97.
Gear 6
1
2
3
4
5
6
Remove the gear (8).

Dissemble the clutch (7).
Remove the support plate (11).
Slide the clutch of the axle.
Remove gear 6.
Gears 4 and 12
1
2
3
Remove the support plate (11) to free the intermediate axle (13) with its components.
Remove the bearings, washers and spring clip from the axle.
Slide the gears (4 and 12) from the axle.
Gear 17
1
2
3
4
5
6
Remove the insert table to get access to the transportation axle.

Remove the spring clip, washer and bearing at the left-side of the transportation axle (2).
Move the axle a little to the right-hand side.
Slide the gear (17) to the left-hand side.
Remove the cyl. pin.
Gear 19
The gear (19) is mounted to the transportation axle (1) by a tension pin. To remove this gear:
1
2
3
4
5
6
Remove the insert table.

Remove the spring clip, washer and bearing from the left-hand side of the axle.
Slide the rollers to the right-hand side to remove the cyl. pins.
Slide the axle to the right-hand side out of the right-hand inside frame. Take care of the
two rollers.
Tap the tension pin.
Remove the gear (19) from the axle.
Clutches
Slip clutch envelope feed axle
1
2
3
4
Remove the metal ring of the pulley (9).

Slide the belt (5) of the pulley (9).
Remove the pulley from the axle.
Slide the slip clutch of the axle.
rev. 1.0 - 12/2009
5-51
075.1
Service Manual
Clutch CW
When the machine is switched on the gear (6) it is constantly driven. By activating the clutch
(7) all the gears shown in the figure on page 5-49 and the accompanying axles and rollers of
the envelope feed and envelope track will be driven. So to feed, open and place an envelope on
the insert table the clutch (7) is activated.
To remove the clutch (7):
1
2
3
Remove the support plate (11) and the gear (8).

Slide the clutch (7) of the axle.
5-52
rev. 1.0 - 12/2009
Service Manual
075.1
Power supply assy. and main motor (M2)

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

1
2
3
4
Remove the main lead.

Remove the power supply cover (2).
Disconnect all wiring.
LH
5
6
Remove the two countersunk head screws (4) and the two round head screws (7) securing
the power supply assy.
Pull the power supply assy. out of the machine.
rev. 1.0 - 12/2009
5-53
075.1
Service Manual
Note
When replacing the power supply assy., ensure that the guide plates 1 (refer to the figure on
page 5-53) are fitted correctly in the guide rollers. Also take care to fit the microswitch
correctly and ensure the correct functioning.
Main motor M2
RH
8
76
To remove the main motor:

1
2
3
4
5
Release the belt tensioner (5)

Remove the belt (2).
Remove the bottom plate of the machine.
Remove the four screws (6) and the washers (7).
Withdraw the motor (8) from the machine. Take care of the wiring.
Note
For belt adjustment, see Section Main drive PJ-belt on page 5-88, and Section Main drive
belt inserter on page 5-90.
5-54
rev. 1.0 - 12/2009
Service Manual
075.1
5.2.10 (Dis)assembly - Envelope hopper

Remove the feed platform
1
2
3
4
5
Move the side guides as wide as possible.

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

1
2
Remove the feed platform as described in section Remove the feed platform on
page 5-55.
Pull the rear cover (3) downwards from behind the frame rod (4) and withdraw it in the rear
side direction (part numbers according to figure on page 5-55).
rev. 1.0 - 12/2009
5-55
075.1
Service Manual
O-rings
8 9 10 11
2 3 4 5
6 7
Removal
1
2
3
4
5
Remove the feed platform (see Remove the feed platform on page 5-55).
Remove the spring clips, washers, bearings, etc. (1) from both sides of the feed shaft (5).
Shift the feed shaft in the right-hand side direction until it clears the LH inside frame.
Tilt the left-hand side of the feed shaft in the rear side direction and when possible withdraw
it in the left-hand side direction.
Push the O-rings (2) from the two joggers (3) and remove them from the feed shaft.
Rollers
Separation roller, removal
Note
Before removing the separation roller, first check the adjustment procedure as described in
section Separation roller on page 5-96.
1
2
3
4
5
6
7
Pull down the envelope separation lever.

Slacken the two set screws (7) of the feed roller (6) (part numbers according to figure on
page 5-56).
Slide the feed roller in the left-hand side direction against the jogger (3).
Remove the round head screw (9).
Loosen set screw (8).
Withdraw the rod (11) with the separation roller (10).
Slide the separation roller from the rod.
5-56
rev. 1.0 - 12/2009
Service Manual
075.1
Feed roller, removal

1
2
3
4
5
6
Remove the feed shaft as described in section O-rings on page 5-56.

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

1
2
Position the feed roller in the middle of the feed shaft and the removed jogger at the same
distance from the feed roller as the other jogger.
Ensure that the set screws of the feed roller and the jogger are tightened onto the flattened
part of the feed shaft.
rev. 1.0 - 12/2009
5-57
075.1
Service Manual
Envelope track
Lower rollers
1 2 3 4 5
RH
LH
13 12 11 10
1
2
3
4
5
Remove the bottom plate.

Remove the spring clip, washer and bearing (spring loaded) from the axle of the first set of
the rollers (13).
Move the axle to the left-hand side to free the cyl. pins.
Remove the cyl. pins.
Lift the axle and slide the rollers of the axle. Take care of the pressure spring of the
bearings.
Note
Remove the second set of rollers (12) in the same way.
Remove the inner two rollers in the same way.
To remove the third set of rollers (11), first remove the outer two rollers (10).
5-58
rev. 1.0 - 12/2009
Service Manual
075.1
RH
2 3 4 5 6 7 8 9 1011
12
13
14
22
21
LH
18 17 16 15
20 19
6
7
8
9
10
Remove the flap scraper (21).

Remove the pressure springs (15) of the bearings of the fourth set of rollers (19).
Slide the rollers to the left-hand side to remove the cyl. pin.
Remove the spring clips.
Slide the axle to the right-hand side and remove the rollers (19) from the axle.
Note
For adjustments of the flap scraper, see Section Flap scraper on page 5-98.
rev. 1.0 - 12/2009
5-59
075.1
Service Manual
Upper rollers
1
2
3
4
5
6
Remove the insert table as described in Section 5.2.12 (Dis)assembly - Envelope

transport on page 5-69.
Slide the first set of rollers (5) of the axle (7).
Remove the cyl. pins (4).
Remove the spring clip (1), washer (2) and bearing (3) at the left-hand side of the axle (7).
Slide the axle to the right-hand side.
Remove the rollers from the axle.
Note
Remove the second and third set of rollers in the same way.
1
2
3
4
5
6
Remove the insert table to get access to the fourth set of rollers of the envelope track.
Remove the fixing plate envelope track (8, figure on page 5-58) to get more room.
Slide the rollers (10) aside to remove the cyl. pins.
Remove the spring clip, washer and bearing at the left-hand side of the axle.
Remove the rollers from the axle.
Rubber roller
1
2
3
4
5
6
7
Remove the insert table and the transportation table (19 in figure on page 5-69).
Slide the transportation table in the direction as indicated, over the second fold roller.
Remove the knob (1) and the spring clips (5) of the rubber roller (11).
Remove the gear at the right-hand side of the rubber roller as described in Section Gears
on page 5-50.
Slide the roller to left-hand side to free the right-hand side of the rollers from the right-hand
inside frame. Take care of the bearing.
Lift the right-hand side.
Withdraw the rubber roller from the machine.
5-60
rev. 1.0 - 12/2009
Service Manual
075.1
Finger solenoid
RH
1
2
3
4
Remove the draw bar (3).

Remove the tension spring (4).
Disassemble the mounting bracket (2) with the solenoid (1).
Remove the solenoid (1) from the bracket (2).
Note
For adjustments of the solenoid, see Section Solenoids on page 5-94.
rev. 1.0 - 12/2009
5-61
075.1
Service Manual
5.2.11 (Dis)assembly - Upper unit

Drive mechanism
The drive mechanism of the upper unit is located at the right-hand side of the machine.
1
2
3
4
5
6
7
8
Belt
1
2
Slide the belt (7) of the pulley (6).

Remove the belt from pulley (8).
Pulleys
Pulley 8:
1
2
Remove the spring clip of the pulley (8).

Slide pulley (8) from the axle.
5-62
rev. 1.0 - 12/2009
Service Manual
075.1
Pulley 6:
1
2
Remove the spring clip and washer.

Slide pulley/gear (6) from the axle.
Gears
Gear 6:
See the previous section (pulley (6)).
Gear 5:
1
2
3
4
5
6
7
8
9
10
Open the upper unit.

Remove the six screws by which the brake plate (1) is mounted to the upper frames. Take
in account the weight of the upper unit when removing the dampers.
Close the upper unit and remove the axle (2).
Move the brake plate (1) with assembled components carefully aside. Take care of the
wiring to the solenoid, the sensor and display.
Remove the plate (3).
Remove the spring clips of the axle (4).
Remove the cyl. pins of the rollers.
Slide the axle (4) to the right-hand side out of the frame.
Tap the tension pin of the gear (5).
Document inserting
RH
LH
12
11
10
Rollers
1
2
3
Remove the guide plates (1) and (4) on both sides.

Slide the upper insert rollers (2) of the axle. Take care of the cyl. pins.
Slide the first set of ejection rollers (12) of the axle. Take care of the cyl. pins.
rev. 1.0 - 12/2009
5-63
075.1
Service Manual
RH
LH
To remove the second set of ejection rollers:

1
2
3
4
5

Remove the roller (4) from the axle.
Tap out the cyl. pin of the roller (1) and slide the roller from the axle.
Gears
1
2
3
4
5
6
Remove the guide plates (1) and (4) on both sides.

Remove the bracket (6) and the sensor. Take care of the wiring of the sensor.
Remove the pulley (5) and the spring clip (10).
Slide the outer bearings from the axle (8).
Remove the tension springs (3).
Slide the axle (8) with complete insert assembly through the slotted holes out of the frames.
5-64
rev. 1.0 - 12/2009
075.1
8
7
10
11
LH
RH
Service Manual
Refer to the figure above.

1
2
Remove the frame plate (5).

Slide the gears (4, 7 and 8) of the axles. Take care of the pressure springs (6).
rev. 1.0 - 12/2009
5-65
075.1
Service Manual

1
2

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

1
2
Remove the frame plate (9).

Slide the gears (10 and 11) from the axles.
Ejection solenoid
1
2
3
4
Remove the covers of the loc, to get access to the solenoid. See Section Right-hand side
cover on page 5-7.
Disconnect the wiring of the solenoid.
Remove the solenoid (2). Take care of the plunger (1), the washers, and the pressure
spring.
Note
5-66
rev. 1.0 - 12/2009
Service Manual
075.1
rev. 1.0 - 12/2009
5
4
LH
RH
Envelope transport and sealing
5-67
075.1
Service Manual
Rollers
Sealing transport rollers
1
2
3

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

Refer to Section Pulleys on page 5-62.
Upper reverse rollers
1
2
Remove the accompanying spring clips and washers.

Slide the rollers (7) of the axle.
Sealing solenoid
1
2
3
Disconnect the wiring of the solenoid (1).

Withdraw the solenoid. Take care of the pressure spring and the washers at the plunger.
Note
Brush solenoid removal
1
1
2
3
Disconnect the wiring of the solenoid (2).

Withdraw the solenoid. Take care of the spacer and plunger.
5-68
rev. 1.0 - 12/2009
Service Manual
075.1
LH
1 2
22 21
20 19
18 17
5 6 7
8 9 10 11 12
13
14 15 16
RH
5.2.12 (Dis)assembly - Envelope transport
Lower ejection rollers

1
2
Remove two screws (13) of the insert table (19) and four screws (1) of the guide plate (2).
Remove the drive belt inserter as described in Section Drive belt inserter on page 5-48.
rev. 1.0 - 12/2009
5-69
075.1
3
4
5
6
7
8
9
Service Manual
Remove the locking plate of the bearing at the right-hand side of the transportation axle
(20).
Slide the axle (20) to the right-hand side.
Remove the cyl. pin (17).
Slide the roller (18) from the axle.
Remove the spring clip, washer and bearing from the left-hand side of the axle (22).
Slide the axle to the right-hand side.
Slide the rollers (21) from the axle.
Sealing track transportation rollers

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

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

1
2
3
4
Remove the pressure springs (16) from the bearings (15) of the axle (8).
Slide the rollers (4) aside to remove the cyl. pins (3).
Remove the spring clip, washer and bearing at the left-hand side of the axle.
Slide the rollers of the axle.
Note
Take care of the pressure springs (16) when replacing again. On the left-hand side a spring
with lower force than on the right-hand side has to be fitted.
5.2.13 (Dis)assembly - Envelope sealing and ejection
Upper sealing roller
1
2
3
4
Remove the gear at the right-hand side of the sealing roller (6). Refer to Section Gears
on page 5-50.
Remove the pressure springs (11) from the bearings (12) and the spring clip at the lefthand side of the sealing roller. Take care of the washer (10) and the spring (9).
Move the sealing roller (6) to right-hand side to free the left-hand bearing from the lefthand inside frame.
Withdraw the upper sealing roller.
Lower sealing roller

1
Remove the upper sealing roller. Refer to the previous section.
Remove the gear at the right-hand side of the sealing roller (5). Refer to Section Gears
on page 5-50.
Remove the two screws (14) and the mounting plate (7).
Remove the spring clip, washer and bearing at the left-hand side of the lower sealing roller
(5).
Move the sealing roller to the right-hand side.
Withdraw the lower sealing roller.
2
3
4
5
5-70
rev. 1.0 - 12/2009
Service Manual
075.1
5.2.14 (Dis)assembly - Sensors

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

Cut the wire strap.
Remove the bracket (2) together with the safety switch (1).
Remove the safety switch from the bracket.
rev. 1.0 - 12/2009
5-71
075.1
Service Manual
Safety switch LH side cover
LH
1
The safety switch is located at the left-hand side of the machine near the sealing rollers. To
remove the safety switch (3):
1
2
3
Open the left-hand side cover.

Remove the cover (1).
Remove the safety switch (3) from the bracket (2).
5-72
rev. 1.0 - 12/2009
Service Manual
075.1
Safety switch collator area
RH
The safety switch is located at the right-hand side beneath the collator area and behind the
supply cover. To remove the safety switch (2):
1
2
Remove the supply cover.

Remove the safety switch (2) from the frame (1).
rev. 1.0 - 12/2009
5-73
075.1
Service Manual
Sealing liquid reservoir switch
1
1
2
Remove screws (2).

Remove the bracket (1) from the frame.
5-74
rev. 1.0 - 12/2009
Service Manual
075.1
DFC and photocells

Note
Whether or not photocells are replaced, it is advised to reset the photocells after finishing
servicing.
Feeder DFC
1
RH
LH
Each feeder is equipped with a DFC. To remove the DFC:
1
2
3
4
Remove the covers (1, 2, 3 and 4). Refer to Section Automatic separation feeder (with
daily mail) on page 5-25.
Remove the guide plate (5), when removing the DFC of the middle feeder. Refer to Section
Middle feeder (feeder 2) on page 5-22.
Disconnect the wiring of the DFC.
Remove the screw (2) securing the DFC (3) to the bracket (1).
rev. 1.0 - 12/2009
5-75
075.1
Service Manual
Feeder photocell
2 1
RH
4 3
LH
Transmitter (LED)
1
2
3
Remove the bracket (4) with the transmitter (3).

Disconnect the transmitter.
Remove the transmitter from the bracket.
Receiver (Sensor)
1
2
Disconnect the sensor (1).

Remove the sensor from the bracket (2).
5-76
rev. 1.0 - 12/2009
Service Manual
075.1
Vertical track photocell
Transmitter (LED)
1
2
3
4
Open the loc.

Remove the guide plate (1) with the assembled transmitter (2).
Disconnect the wiring of the transmitter.
Remove the transmitter.
Receiver (Sensor)
1
2
3
4
5
Remove the vertical transport cover.

Cut the wire strap securing the wiring of the sensor (3) to the bracket (4).
Remove the bracket with the sensor.
Disconnect the wiring.
Remove the sensor.
rev. 1.0 - 12/2009
5-77
075.1
Service Manual
Collating area slotted photocell
LH
1
2
Remove the set screw (1) and the pulse disc.

Remove the slotted photocell (2).
Note
Ensure on replacement that the pulse disc sensor clears both sides of the pulse disc.
5-78
rev. 1.0 - 12/2009
Service Manual
075.1
Collating area photocell
2
3
4
5
6
7
RH
LH
Transmitter (LED)
1
2
3
4
5
Move the lower collator arm downwards.

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

Remove the sensor (2) from the guide plate.
Folder entry photocell

Transmitter (LED)
1
2
3
Remove the bracket (5) with the transmitter (6) to the left-hand side out of the left-hand
inside frame. Take care of the wiring.
Remove the transmitter (6) from the bracket.
Receiver (Sensor)
1
2
3
Remove the bracket (5) with the transmitter (6) to the left-hand side out of the left-hand
inside frame. Take care of the wiring.
Remove the receiver (7) from the bracket.
rev. 1.0 - 12/2009
5-79
075.1
Service Manual
Folder slotted photocell
LH
The sensors are located at the left-hand side of the upper unit. To remove the sensor:
1
2
3
4
5

Remove the bracket (1) with the sensor (2).
Cut the wire strap.
Disconnect the sensor.
Remove the sensor from the bracket.
Note
The sensor (3) can be removed in the same way.
5-80
rev. 1.0 - 12/2009
Service Manual
075.1
Inserter slotted photocell
1
2
3
4
RH
The pulse disc sensor assy. is located at the right-hand side of the machine near the sealing
rollers. To remove the sensor:
1
2
3
4

Disconnect the wiring of the sensor (2).
Remove the sensor.
Note
Ensure on replacement that the pulse disc sensor clears both sides of the pulse disc. To adjust
the position of the sensor, slacken screw (1), reposition the sensor and fasten screw (1).
rev. 1.0 - 12/2009
5-81
075.1
Service Manual
Envelope track photocell
RH
RH
LH
LH
Transmitter (LED)
1
2
3
4
5

Pull the air hose connector (4) from the transmitter (3).
Slacken the screw of the transmitter.
Remove the transmitter (3).
Receiver (Sensor)
1
2
3
4
5

Remove the bracket (2) together with the sensor (1).
Slacken the screw of the sensor.
Remove the sensor (1).
5-82
rev. 1.0 - 12/2009
Service Manual
075.1
Flap cell
3
4
5
6
Transmitter (LED)
1
2
3
4

Remove the bracket (1) with the transmitter (2). Take care of the wiring.
Disassemble the transmitter from the bracket.
Receiver (Sensor)
1
2
3
4
5
6

Pull the air hose connector (3) from the sensor (4).
Slacken the screw (6).
Remove the sensor from the bracket.
rev. 1.0 - 12/2009
5-83
075.1
Service Manual
Insert table photocells
RH
LH
RH
LH
Transmitter (LED)
1
2

Remove the screw (1) to release the transmitter (2).
Receiver (Sensor)
1
2
3
4
Remove the transport table.

Remove the sensor from the bracket. Take care of the wiring.
5-84
rev. 1.0 - 12/2009
Service Manual
075.1
Closer photocell
1
Transmitter (LED)
1
2
3
Slacken screw (4).

Remove bracket (2) with the transmitter (3).
Remove the transmitter from the bracket.
5 6
RH
LH
Receiver (Sensor)
1
2
3
4
Remove the nuts (1 and 7).

Remove the frame (2) complete. Take care of the wiring.
Remove the bracket (4) with the photocell (6).
rev. 1.0 - 12/2009
5-85
075.1
Service Manual
Exit photocells
RH
LH
1
2
3
Remove the frame axles (1) together with the cover (2). Take care of the wiring of the
detectors.
Remove the transmitter (LED, 3).
Remove the receiver (sensor, 4).
5-86
rev. 1.0 - 12/2009
Service Manual
075.1
Sealing liquid level sensor
1
1
2
Remove screws (2).

Remove the bracket (1) from the frame.
rev. 1.0 - 12/2009
5-87
075.1
Service Manual
5.2.15 Adjustment
Main drive PJ-belt
10 mm (0.4 inch)
1
The maximum movement of the drive belt at the indicated position is 10 mm (0.4 inch).
To adjust:
1
2
3
4
Slacken the two screws (1) securing the belt tensioner (2).
Shift the belt tensioner to adjust the correct belt movement.
Hold the belt tensioner in position and retighten the two screws.
Check the adjustment and readjust if necessary.
Note
Do not adjust the drive belt too tight.
Note
When adjustment of the belt tensioner is not sufficient, re-adjust the motor position.
5-88
rev. 1.0 - 12/2009
Service Manual
075.1
Main drive belt feeders/folder
10 mm (0.4 inch)
To adjust:
1
2
3
4
Note
rev. 1.0 - 12/2009
5-89
075.1
Service Manual
Main drive belt inserter
10 mm (0.4 inch)
To adjust:
1
2
3
4
Note
5-90
rev. 1.0 - 12/2009
Service Manual
075.1
RH drive belts
Note
The adjustment of the lower and upper drive belt is similar.
upper drive belt
3
2
1
5 mm (0.2 inch)
lower drive belt
The maximum movement of the drive belts (1) at the indicated position is 5 mm (0.2 inch).
To adjust:
1
2
3
4
Slacken the hexagonal head screw (3) securing the belt tensioner (2).
Hold the belt tensioner and retighten the hexagonal head screw.
Note
rev. 1.0 - 12/2009
5-91
075.1
Service Manual
Drive belt upper folder section
5 mm (0.2 inch)
The maximum movement of the drive belts at the indicated position is 5 mm (0.2 inch).
To adjust:
1
2
3
4
Slacken the hexagonal head screw (1) securing the belt tensioner (2).
Hold the belt tensioner and retighten the hex. head screw.
Note
5-92
rev. 1.0 - 12/2009
Service Manual
075.1
Paper guide
There must be a small gap between the fixed guide plate (3) and the fold roller (2). The fold
roller should just run free.
To adjust:
1
2
Slacken the two round head screws (1) to move the guide plate (3) further away from the
fold roller (2).
Tighten it to move it closer.
rev. 1.0 - 12/2009
5-93
075.1
Service Manual
Solenoids
Note
The adjustment procedure for all solenoids is described below. Only for the finger solenoids a
different procedure is necessary.
Whenever a solenoid is actuated the plunger is pulled into the solenoid coil. To make sure that
the pulling power of the solenoid coil on the plunger is maximal, the plunger should not touch
the bottom of the solenoid coil whenever the solenoid is actuated.
LH
RH
To set this requirement:
1
2
3
4
5
Slacken the two screws (3) securing the solenoid coil (4).
Push the plunger (2) together, with the linkage (1) attached to it, as far as it will go in the
direction towards the solenoid coil.
Hold the plunger in this position and then slide the solenoid coil towards the plunger until
the plunger bottoms the solenoid coil.
Move the solenoid coil back by approximately 1 mm (0.04 inch).
Retighten the two screws. Ensure the solenoid coil and the plunger are aligned in a straight
line.
5-94
rev. 1.0 - 12/2009
Service Manual
075.1
Finger solenoid
RH
1
To adjust the finger solenoid:

1
2
3
4
Slacken the two screws (2) securing the solenoid coil (1).
Push the plunger (3) down into the lowest position.
Move the solenoid coil (with the plunger in the lowest position) so that the middle fingers
(slide in) is adjusted approximately 2 mm (0.07 inch) (max.) above the insert table.
Retighten the two screws.
rev. 1.0 - 12/2009
5-95
075.1
Service Manual
Separation roller
Because the separation roller does not reverse, a 'flat' gradually wears on the roller surface. This
can be the cause of irregular feeding of the envelopes. Should this occur, carry out the following
adjustment:
1
2
3
4
Pull down lever (3).

Slacken screw (2) to rotate separation roller (1).
Rotate the separation roller about 60 degrees in the direction indicated, so that the unworn
portion of the separation roller faces the feed roller.
Fasten screw (2).
Close lever (3).
Note
After rotating the separation roller over 300 degrees it is necessary to replace it.
Note
If you have to turn the separation roller that far that screw (2) turns out of reach, move screw
(2) to the next hole in the separation roller.
5-96
rev. 1.0 - 12/2009
Service Manual
075.1
Friction brake
20 mm (0.79 inch)
The friction brake is correctly adjusted when the distance between the inner faces of the two
friction discs (3), i.e. the overall pressure spring length, is 20 mm (0.79 inch).
To adjust:
1
2
3
Remove the outer nut (1) securing the inner nut (2).
Turn the inner nut to adjust the correct distance.
Replace the outer nut and check the adjustment.
Note
An increased variation of the envelope stop position can be caused by excessive play in the
lower gear train. A slight reduction in the distance (increasing the pressure) may give the
required result.
rev. 1.0 - 12/2009
5-97
075.1
Service Manual
Flap scraper
RH
LH
The flap scraper (3) must be positioned so that its lower edge is aligned with the lower edge of
the envelope guide (1).
To adjust:
1
2
3
Slacken the two hexagonal head screws (2) securing the flap scraper (3) on both sides.
Move the flapscraper to adjust the correct position.
Retighten the two hexagonal head screws and check the adjustment.
Note
Depending on the envelope type and flap shape, a different setting may be necessary.
5-98
rev. 1.0 - 12/2009
Service Manual
5.3
Electrical description
5.3.1
075.1
PCBs
An overview of all PCBs:
Board number
Board name
2994502X
Display board
2994508D
Keyboard
2975540V (110 V) or
2975500D (220 V)
Motor relay board
2992003U (regular) or
2992001S (expanded) (optional)
2992002T (optional)
Connection board
2992000R (optional)
Communication board
2825900V or
2825942P
Main board
Pre-programmed main board
2994504Z
ID Tag
rev. 1.0 - 12/2009
Modem board
5-99
075.1
5.3.2
Service Manual
Display board
Wiring display board
LC display
Connector number
Cable number
J100
2989082B
J101
LC display CCFL
J103
LC display touchscreen
J104
LC display data
J210
2989082B
LC display
data
2994544R
LC display
y
CCFL
2994544R
5-100
rev. 1.0 - 12/2009
Service Manual
5.3.3
075.1
Keyboard
2994544R
Wiring keyboard
Connector number
Cable number
J100
2994544R
rev. 1.0 - 12/2009
5-101
075.1
5.3.4
Service Manual
Motor relay board
2
2994526X
2
2994526X
2
2994526X
Wiring motor relay board
main motor
Connector number
Cable number(s)
J1
2994526X
J2
2994526X
X
2994526X
X
not in
use
2994526X
Main motor
115 V: 2989407Q
230 V: 2989406P
J3
not in use
51
2994526X
52
2994526X
54
2994526X
55
2994526X
124
2994526X
5-102
rev. 1.0 - 12/2009
Service Manual
5.3.5
075.1
Connection board
a. Connection board, regular
2994532D
D
Wiring connection board (regular)
Connector number
Cable number
J101
2994532D
rev. 1.0 - 12/2009
5-103
075.1
Service Manual
b. Connection board, expanded (optional)
Wiring connection board (expanded)
2994532D
2994532D
Connector number
Cable number
J105
2994532D
J108
2994532D
Modem board
The modem board is attached to the expanded connection board.
5-104
rev. 1.0 - 12/2009
Service Manual
5.3.6
075.1
Communication board (optional)
rev. 1.0 - 12/2009
5-105
075.1
Service Manual
2
2994548V
2
2994532D
2
2994534F
2
2994532D
Wiring communication board
2994534F
F
Connector number
Cable number
J101
2994534F
J401
2994532D
J402
2994548V
J403
2994532D
J502
2994534F
5-106
rev. 1.0 - 12/2009
Service Manual
075.1
Testpoints and LEDs on the communication board
TP102
TP101
D201
D202
D203
D204
D205
D206
D302
TP207
TP208
TP202
TP206
TP207
TP105
TP203
TP201
TP106
rev. 1.0 - 12/2009
5-107
075.1
Service Manual
Testpoint
Name
Typical value
Function
TP101
GND
0V
Debug ground
TP102
GND
0V
Debug ground
TP105
+24V
24 V
Supply check
TP106
GND
0V
Electrical ground
TP201
SDO
Debug only
TP202
SDI
Debug only
TP203
SCLK
Debug only
TP205
PB 5
Debug only
TP206
PB 6
Debug only
TP207
PB 7
Debug only
TP208
PFO/CAL
Debug only
LED
Color
Name
Function
D201
Green
TestLED 0
No error heartbeat
D202
Green
TestLED 1
Modem activity
D203
Green
TestLED 2
Inserter communication activity (USB link)
D204
Green
TestLED 3
Franking interface (FIF) communication activity
D205
Green
TestLED 4
Service communication activity
D206
Green
TestLED 5
Debug LED
D302
Red
Flsh wrt
Flash write in progress indication
5-108
rev. 1.0 - 12/2009
Service Manual
5.3.7
075.1
Main board
rev. 1.0 - 12/2009
5-109
075.1
Service Manual
2
2989018K
Wiring main board
2825917N
N
2989032Z
Z
2994548V
V
2994534F
2994532D
D
2994530B
B
2
2989036D
2
2825916M
2825916M
M
2825915L
L
2994520R
R
2989022P
P
2989010B
B
5-110
2994536H
2994522T
2825914K
2
2989082B
rev. 1.0 - 12/2009
Service Manual
Connector number
Cable number
J100
2825916M
J101
2989036D
J102
2994526X
J500
2994520R
J501
2989020M
J502
2989022P
J600
2825916M
J602
2994522T
J603
2825914K
J604
2825915L
J650
2994536H
J700
2989010B
J701
2989018K
J800
2989028V
J801
2989024R
J802
2994530B
J901
2989032Z
J902
075.1
2989032Z
2825917N (in case of high capacity feeder)
J903
2989032Z
J904
2825916M
J1000
2989434T (reading head)
J1100
2994532D (without communication board)

2994534F (with communication board)
J1102
2994548V
J1120
2994534F
J1200
2989082B
rev. 1.0 - 12/2009
5-111
075.1
Service Manual
Testpoints and LEDs on the main board
T
TP103
T
TP105
TP901
TP900
T
TP102
TP903
TP902
TP904
TP906
T
TP100
T
TP101
TP800
D801
TP301
D303
TP300
D301
D300
D702
D701
TP205
TP1001
1
T
TP701
TP505
D500
TP600
TP500
TP502
TP501
TP503
5-112
rev. 1.0 - 12/2009
Service Manual
075.1
Testpoint
Name
Typical value
Function
TP100
+5V
5V
Supply check
TP101
-12V
-12 V
Supply check
TP102
+12V
12 V
Supply check
TP103
GND
0V
Electrical ground
TP105
+24V
24 V
Supply check
TP200
Window
5V
OMR window oscilloscope trigger
TP205
DBG5
Debug only
TP300
TST1
Debug only
TP301
TST2
Debug only
TP500
ENV
1.2 V
Envelope photocell
TP501
FLAP
1.2 V
Flap photocell
TP502
LOC
1.2 V
Loc photocell
TP503
EXIT
1.2 V
Exit
TP505
PDSC
5 V or 0 V
Main pulsedisc signal
TP600
CLOSER
1.2 V
Closer photocell
TP700
COLL
1.2 V
Collator photocell
TP701
FO
1.2 V
Folder photocell
TP800
PD COL
5 V or 0 V
Collator pulsedisc
TP900
FE-1
1.2 V
Feeder 1 photocell
TP901
FE-3
1.2 V
Feeder 3 photocell
TP902
DFC FE1
Depends on paper thickness
DFC out feeder 1
TP903
DFC FE3
Depends on paper thickness
DFC out feeder 3
TP904
FE-2
1.2 V
Feeder 2 photocell
TP906
DFC FE2
Depends on the paper thickness
DFC out feeder 2
TP1000
OMR OUT
Depends on the paper reflection and

marks
Analog OMR signal
TP1001
ReadHead
1.2 V
Readhead photocell
rev. 1.0 - 12/2009
5-113
075.1
Service Manual
LED
Color
Name
Function
D300
Green
TST1
No error heartbeat
D301
Red
TST2
Error heart beat
D303
Red
Flash write
Flash write in progress indication
D500
Green
PDSC
Main pulsedisc indication
D701
Green
FT1
Folding table 1 indication
D702
Green
FT2
Folding table 2 indication
D801
Green
PD COLL
Collator pulsedisc indication
Flex OMR
Note
Only use a dongle that is marked with the number 37, DS1977 (see following figure). This
dongle is not downwards compatible for other SI or SA products. Dongles marked with OC must
not be used on the 075.1.
number 37
DS1977
5-114
rev. 1.0 - 12/2009
Service Manual
5.3.8
075.1
ID-tag (2994504Z)
2994536H
Wiring ID-Tag
Connector number
Cable number
J100
2994536H
rev. 1.0 - 12/2009
5-115
075.1
Service Manual
5.4
Maintenance
5.4.1
Preventive maintenance
Average preventive service visits should take place at approximately 160.000 inserts (see
service menu, service counters). The table below shows the intervals.
Please note that there is a statistical relationship between the actual average monthly volume
and the service requirements of the machine. Significant larger average volumes might double
the yearly service requirements.
Maintenance
Number of cycles
Service visit
+/- 160.000
160k
+/- 330.000
160k
+/- 500.000
500k
+/- 660.000
160k
+/- 830.000
160k
+/- 1.000.000
500k
10
+/- 1.660.000
160k
11
+/- 1.800.000
160k
....
....
Note
It is recommended to service the machine at least twice a year.
Note
If the high capacity vertical stacker is installed (HCVS-1), refer to 10.5.3 Preventive
maintenance on page 10-54 for the maintenance schedule of the HCVS-1.
5-116
rev. 1.0 - 12/2009
Service Manual
5.4.2
075.1
160k Service visit
Estimated time to do the 160k service is 1 hour.

General
Check with the operator if there are any problems detected.
Visual inspection.
Vertical
Clean the photocells and check the function via the service menu.
Check the alignment of the document hoppers.

Document feeders
Replace the separation rollers (upper + lower) of the automatic separation feeder.
Check the separation function of the special feeder.
Replace all paper pullers of the feeders.

Inserter
Clean the sealing and closing area of the inserter.
Clean the photocells and check the function via the service menu.
Description
Page
Item
Part
Quantity
page 9-41
2951167G
Rubber paper puller
page 9-41
13
2040016R
Separation roller (lower)
page 9-42
59
2951168H
page 9-41
2951167G
2*
Rubber paper puller
page 9-41
13
2040016R
page 9-42
59
2951168H
2*
Feed roller kit 3 station expert
Feed roller kit 2 station expert
(*) Depending on the configuration
rev. 1.0 - 12/2009
5-117
075.1
5.4.3
Service Manual
500k Service visit
Estimated time to do the 500k service is 3 hours.

Additional parts to be replaced at each 500k.
Description
Page
Item
Qty.
Remarks
2040306T
Moistening cloth
Part
1 for spare
Feed roller 42 mm
page 9-13
13
2732731U
Jogger roller O-ring
page 9-13
2041876D
Finger
page 9-23
36
2964071Y
Transportation roller 30 mm
page 9-27
27
2964364D
At insert
Brush
page 9-29
19
2720005N
3 for spare
Collating belt set (3 pcs.)
page 9-55
30
2952007G
Pressure roller inc. O-ring (assy)
page 9-55
21
2952011L
Transportation table (assy)
page 9-23
47
2964567Q
Transportation roller 38mm
page 9-29
28
2042977A
General
Check with the operator if there are any problems detected.
Visual inspection.
Vertical
Clean the rollers of the vertical track.
Clean the collating belts and check the tension of the belts.
Check the tension of the driving belts.
Slightly lubricate the bearings.

Document feeders
Clean the rollers per feeder.
Clean the freewheel clutch in Pulley 28T- see item 14 on page 9-41 in Section 9.17
Document feeder unit (automatic) - and lubricate it lightly.
Clean the freewheel clutch in Gear 64T assy - see item 38 in Section 9.18 Document feeder
unit - special 1/2 - and lubricate it lightly.
Clean the thickness detector and check it via the service menu.
Envelope track
Check the separation roller, turn it a little inwards when a flat side is present.
Replace the feed roller - see Rollers on page 5-56.
Replace the O-rings of the jogger rollers.
Clean the rollers of the envelope track.
Check if the rollers are still clicked correctly.
5-118
rev. 1.0 - 12/2009
Service Manual
075.1
Inserting area + loc + exit
Replace the transportation rollers 30mm - see item 26 in Section 9.10 Insert and eject
mechanism - which are placed above the lower insert rollers.
Clean other rollers in the loc.
Clean braking plate assy. and cover loc - see items 9 and 21 in Section 9.12 Envelope
closing mechanism.
Replace the brushes and the moistening cloth.
Clean the upper and lower sealing rollers.
Clean the lower insert rollers.
Replace all the fingers.

Drive mechanism
Check the chain tension, lubricate lightly if necessary.
Check the belt tension.
Clean the pulse disc and the accompanying sensor.
Lightly lubricate the bearings.
rev. 1.0 - 12/2009
5-119
075.1
5-120
Service Manual
rev. 1.0 - 12/2009
Service Manual
6
075.1
Fault finding
There are three kinds of errors:
Hardware related errors that make further paper processing impossible. The error screen
displays a call service pictogram.
Hardware related errors at which further paper processing is still possible.
Operational errors, in most cases paper flow errors.

An error may result into:
A soft stop. An error situation forces the machine to stop. After solving the problem the
process can be resumed. The machine part with the problem is directly stopped, but in other
machine parts envelopes and documents are transported to the next stop position.
A hard stop. An error forces the machine to stop and the process cannot simply resumed
after solving the error. The machine must be switched off. An example of a hard stop is the
opening of a microswitch-guarded cover. All main motor-driven moving parts of both the
system are abruptly stopped. The process timing (based on pulses delivered by slotted
photocells) is completely disrupted.
If an error occurs in one of the parts of the system, an error screen
is displayed. The display shows a screen showing the following
information:
An indication of the area in which the error occurred.
An error description.
A suggested solution behind the pointing hand.

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

If a feeder hopper is empty the machine continues the process until the last complete set is
handled.
As far as simultaneous errors in various system parts are concerned the priorities are: inserter,
folder, vertical transport, feeder.
6.1
Resolve problems remotely
For remotely diagnosing customer problems, check the following with the customer:
The machine type and serial number:

1
Look on the sticker (on the internal frame)
2
Open the front cover
3
Read the machine type and serial number
The customer's Failure description. See Section 10.3.1 Failure symptoms.
The error message coming with the failure. This can be checked by the supervisor:
1
Enter the supervisor menu
2
Select system info
3
Read the last error
4
Check the counter since last service visit
5
Check the software versions installed
rev. 1.0 - 12/2009
6-1
075.1
Service Manual
In case of a system with connectivity to online services, ask the supervisor to make a
manual connection.
Select a follow up process:
1
Guide the supervisor through a remote resolution process (with or without online
services). A trained remote service engineer needs to be consulted.
2
When sufficient cycles have been done since last service visit, schedule a preventive
maintenance visit. Schedule enough time for both the engineer and the customer.
3
When there is no clue about the exact cause of the failure, schedule a corrective
maintenance resolution process. A trained field engineer needs to be consulted.
6.2
Troubleshooting Online Services
If it is not possible to connect the machine to the server, use this troubleshooting table to find
the cause.
No sound after pressing
"Connect"
Check if the preparations described in 7.7.1 Preparations on page 7-1 are

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

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

Check the telephone number, the telephone number can be found on Neoweb.
Check in the service menu the IP address:
192.168.20.217 (Europe)
172.16.100.10 (USA)
Main menu -> Supervisor menu (pin 4351) -> Online Services -> Server port
Check in the service menu the Port number:
5001 (Europe)
1003 (USA)
Check in the service menu Suffix: Osiris.FR.FT
System stops automatic
call
6.3
The system stops the automatic call if the call fails three times. Execute a
manual call. This also reschedules the automatic calls.
Error handling inserter
After pressing the i button in an error message screen, the display can show an error code.
6-2
rev. 1.0 - 12/2009
Service Manual
075.1
The error format of inserter errors is as follows: INS-XXX-YYY. The FRM messages are explained
in 6.4 Error handling franking machine on page 6-25. XXX is an abbreviation that indicates a
specific machine part. The following machine areas/prefixes apply:
XXX
Explanation
Reference
BAT
Battery
6.3.1 Battery errors (BAT) on page 6-4
CL
MPPC errors
6.3.2 MPPC errors (CL) on page 6-4
CLS
Closer
6.3.3 Closer errors (CLS) on page 6-4
COM
Communication
6.3.4 Communication errors (COM) on page 6-5
CT
Collator
6.3.5 Collator errors (CT) on page 6-6
DC
DFC
6.3.6 DFC errors (DC) on page 6-6
DF
Document Feeder
6.3.7 Document feeder errors (DF) on page 6-7
DG
Dongle
6.3.8 Dongle errors (DG) on page 6-7
EH
Envelope Hopper
6.3.9 Envelope hopper errors (EH) on page 6-8
EOP
Envelope Open
6.3.10 Envelope open errors (EOP) on page 6-8
FOL
Folder
6.3.11 Folder errors (FOL) on page 6-9
INS
Insert
6.3.12 Insert errors (INS) on page 6-9
JOB
Job
6.3.13 Job errors (JOB) on page 6-10
LD
Level Detector
6.3.14 Level detector errors (LD) on page 6-11
LIC
License
6.3.15 License errors (LIC) on page 6-11
Motor
6.3.16 Motor errors (M) on page 6-12
MOD
Modem
6.3.17 Modem errors (MOD) on page 6-12
OLS
Online service
6.3.18 Online service errors (OLS) on page 6-14
OR
Reading head
6.3.19 Reading head errors (OR) on page 6-15
Photocell
6.3.20 Photocell errors (Pxx) on page 6-15
PB
PCB
6.3.21 PCB errors (PBx) on page 6-18
PD
Pulse Disc
6.3.22 Pulse disc errors (PD) on page 6-18
PRC
Production Control
6.3.23 Production control errors (PRC) on page 6-19
RE
Reading
6.3.24 Reading errors (RE) on page 6-19
SM
State Machine
6.3.25 Machine state errors (SM) on page 6-22
STK
Stacker
6.3.26 Stacker errors (STK) on page 6-22
SW
Switches
6.3.27 Switches errors (SW) on page 6-23
SYS
System
6.3.28 System errors (SYS) on page 6-23
TR
Transport
6.3.29 Transport errors (TR) on page 6-24
rev. 1.0 - 12/2009
6-3
075.1
6.3.1
Service Manual
Battery errors (BAT)
Error
Message
Cause
INS-BAT400
Technical failure
Power dip on communication At IN startup and configuration check

board. OLS error.
(only if OLS is switched on in service
menu).
6.3.2
Information
MPPC errors (CL)
Error
Message
Cause
Information
INS-CL1301
No ID
Scanner did not read an ID.
Check scanning position on envelopes.
INS-CL1302
Invalid ID
The ID of the last envelope is Remove envelope and check why

unknown to BSPI.
envelope ID number is unknown to
integrity control.
INS-CL1303
Duplicate ID
The ID of the last envelope

was already processed
before by BSPI.
INS-CL1304
ID's out of sequence The ID of the last envelope is Remove envelope and check envelope
out of sequence with the
sequence or restart the integrity
previous ones.
control.
INS-CL1900
PC saving problem
BSPI cannot save the ID of

the last envelope in its
database.
Check BSPI application for details.
INS-CL1901
PC problem
The BSPI application

encounters a problem.
Check BSPI application for details.
Information
6.3.3
Remove envelope and check why

envelope has a previously used ID.
Closer errors (CLS)
Error
Message
Cause
INS-CLS110
Envelope closer
failure
Envelope path not cleared

This error is generated if the closer cell
after previous jam, envelope is covered at the moment an envelope/
closing sensor readjustment document should leave the insert area.
needed, dirty sealing track,
insert failures.
INS-CLS111
Envelope closure
failure
Envelope closing path not

cleared after previous jam,
slippage, dirty sealing track,
insert failures, skewing.
INS-CLS290
Unexpected
document at exit
Document which should have Reset to continue.

been removed wasn't
removed.
6-4
This error is generated if the flap closer

sensor is covered too long. Longer than
the time that meets a document
transport of 550 flanks (approx. 275
mm).
rev. 1.0 - 12/2009
Service Manual
6.3.4
075.1
Communication errors (COM)
Error
Message
Cause
Information
INS-COM900
Technical failure
INS-COM901
Technical failure
SCS/I2C protocol problem,

cables, connectors, PCBs.
System error. This error is generated if

something is wrong with the SCS/I2C.
INS-COM902
Technical failure


INS-COM903
Technical failure


INS-COM904
Technical failure


INS-COM905
Technical failure


INS-COM906
Technical failure


INS-COM907
Technical failure


INS-COM908
Communication
failure
Communication failure.
Call service.
INS-COM910
Technical failure
ISIS link down between main Communication lost between inserter

board and communication
and communication board.
board.
INS-COM911
Technical failure
Communication lost between Reset to continue.

inserter and connection
board.
INS-COM930
No communication
Communication error
Check cables and connectors.
between inserter scanner or
BSPI PC.
rev. 1.0 - 12/2009
6-5
075.1
6.3.5
Service Manual
Collator errors (CT)
Error
Message
INS-CT1100
Document transport Document type, document

failure
path blockage, photocells
dusty, photocells defect.
INS-CT1110
Collator stop error
INS-CT1120
Document transport Document set missing from

failure
collator, photocells
readjustments needed,
photocells defect.
This error is generated if no documents

arrive at the folder entry cell. Possible
causes: paper crash or the operator
pressed the stop button, removed the
set from the collator and pressed start.
INS-CT1290
Unexpected
Collator not cleared after
document at collator previous emergency stop.
During initialization of the collator a set

is seen under the folder entry cell. The
collator is initialized after fatal feeder
errors, after collator errors and after a
change of job.
INS-CT1400
Collator stop
reference detection
failed
Zero position sensor failure,

rack broke or collator stop
motor failure.
During initialization of paper stop

detection, the sensor for detecting zero
position could not detect the zero
position.
INS-CT1401
Collator stop
detection failed
Stop position sensor failure,

rack broke or collator stop
motor failure.
During initialization of paper stop

detection the sensor for detecting paper
stop position could not detect the zero
position.
6.3.6
Cause
Information
This error is generated if the collator
entry cell is covered too long. Possible
causes: too stiff material, collator
blocked.
Incorrect collator stop

This error is generated if it takes too
position, mechanical failure. long before a set arrives at the folder
entry sensor. Is only checked at job
start.
DFC errors (DC)
Error
Message
Cause
Information
INS-DC1401
Technical failure
DFC defect, cables defect.
This error is generated in a job where

the DFC is turned on while it is defect.
This error returns after each change of
job.
INS-DC1402
Feeding failure
Document separation failing, This error is generated when the DFC

can not see the difference between
paper being present or not present. This
can be caused by a continuous flow of
paper (no space in between sheets) or
by a defect in the DFC. After reset, a
new reference value is taken. When still
no difference is measured, error INSDC1-402 shows. There is a defect in the
DFC.
INS-DC1402
DFC failure
6-6
This error is generated if the DFC can

not be adjusted.
rev. 1.0 - 12/2009
Service Manual
6.3.7
075.1
Document feeder errors (DF)
Error
Message
Cause
Information
INS-DF1000
Empty feeder
Empty feeders, wrong

document type, document
width setting, manual
document separation
adjustment.
This error is generated if a feeder is

empty. This can be put right by refilling
the feeder and pressing Reset. This is no
fatal error, after restarting the job, the
set will be finished. In order to do a
restart after this error, press the start
button.
INS-DF1110
Document stoppage Blocked document path,

document separation
adjustment (manual
separation only), document
type, document job settings,
photocells dusty.
This error is generated if a feeder

processes a document and it is found
that the document is at least 50%
longer than the document size that was
set up for that feeder in that particular
job. This is a fatal error.
INS-DF1200
Document too short Incorrect document type,

document job settings,
photocell readjustment
needed.

processes a document with a length that
is more than 45 mm shorter than the
document size that was set up for that
feeder in that particular job. This is a
fatal error.
INS-DF1201
Document too long
Document separation
adjustment (manual
separation only, document
type, document job settings,
photocells dusty.

processes a document that is more than
20% longer than the document size that
was set up for that feeder in that
particular job. This is a fatal error.
INS-DF1300
Feeding failure
Incorrect thickness
This error is generated if the sheet on
reference, irregular
which the DFC is adjusted was a double
document types, DFC defect sheet. This error can only be generated
or loose.
with the first sheet that a feeder
processes after adjustment (when this
sheet is thinner than the one that was
used for the adjustment). This is a fatal
error.
INS-DF1301
Document too thick
Document type, document

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

inserts a double page. This is a fatal
error.
6.3.8
Dongle errors (DG)
Error
Message
Cause
Information
INS-DG1400
Technical failure
Incorrect dongle installed,

dongle contents cannot be
read.
OMR error. This error is generated if the

dongle checksum is incorrect or if the
serial number check is incorrect.
rev. 1.0 - 12/2009
6-7
075.1
6.3.9
Service Manual
Envelope hopper errors (EH)
Error
Message
Cause
Information
INS-EH1000
Empty envelope
hopper
Empty hopper, wrong

envelope type, envelope
width setting, envelope
separation adjustment,
envelope feeding angle.
This error is generated if it takes longer

than 15 seconds to detect an envelope
at the envelope track sensor after the
envelope track was started.
INS-EH1200
Envelope too short
Incorrect envelope type,

envelope job settings,
photocell readjustment
needed.
This error is generated if the envelope is

measured shorter than 75 mm. Also
when envelope height is measured
shorter than adjusted envelope height
minus 20 mm.
INS-EH1201
Envelope too long
Envelope separation
adjustment, envelope type,
envelope quality, envelope
job settings, photocells
dusty.
This error is generated if a closed

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

Error
Message
Cause
INS-EOP300
Envelope not open
Envelope exit path, slippage, This error is generated if the envelope

envelope type, inserting
does not arrive within 400 mm (800
failure, flap closer sensor.
flanks) at the exit cell, after detecting
the envelope by the closer switch.
6-8
Information
rev. 1.0 - 12/2009
Service Manual
075.1
6.3.11 Folder errors (FOL)

Error
Message
Cause
Information
INS-FOL100
Folder entry
blockage
Document feeding,
document separation,
document path not cleared
after previous stoppage,
skewing of set, slippage.
This error is generated if the folder

entry cell is covered longer than 500
pulses (about 475 mm). Caused by
incorrect folder transport, or the
document is blocking in collator.
INS-FOL111
Folding failure
Document set thickness,

mechanical defect in first
fold table, folding sensors
defect.
This error is generated if 500 ms after

powering the clutch of the first fold table
no flank is detected on the curve disc
sensor of the first fold table. Possible
causes: fold table blocking by a not
foldable document (stiff material),
mechanical defect on fold table, clutch
or sensor.
INS-FOL112
Folding failure
Document set thickness,

mechanical defect in first
fold table, folding sensors
defect.
This error is generated if 500 ms after

powering the clutch of the second fold
table no flank is detected on the curve
disc sensor of the second fold table.
Possible causes: fold table blocking by a
not foldable document (stiff material),
mechanical defect on fold table, clutch
or sensor.
INS-FOL120
Document stoppage Set not removed after job

change.
This error is generated when paper is

left in the folder after a job change.
6.3.12 Insert errors (INS)

Error
Message
Cause
Information
INS-INS100
Document inserting
failure
Insert fingers, envelope stop

position, envelope job
settings, document skewing,
document, slippage,
document feeding, envelop
feeding.
This error is generated if the insert cell

is covered too long during inserting. Too
long means longer than 400 mm (800
flanks).
INS-INS101
Envelope stoppage
Blocked envelope path,

This error is generated if the flap sensor
envelope separation
is covered more than 690 flanks
adjustment, envelope type, (approx. 345 mm).
envelope job settings, dusty
photocells, slippage.
INS-INS102
Document stoppage Blocked document path,

slippage.
rev. 1.0 - 12/2009
This error is generated if the called

document does not arrive at the insert
cell.
6-9
075.1
Service Manual
Error
Message
Cause
Information
INS-INS103
Insert area blocked
Blocked document or
This error is generated if a document
envelope path after previous covers the insert cell at the moment the
stoppage.
system is started.
INS-INS290
Unexpected
document
Document path not correctly This error is generated if a document

cleared after previous error, arrives at the insert area at a not
slippage, inserting failures.
expected moment.
INS-INS290
Unexpected
document
Document path not correctly This error is generated if the insert cell
cleared after previous error, is covered at the moment a document is
slippage, inserting failures.
called.
INS-INS303
Document length
failure
Insert fingers, envelope stop

position, document job
settings, document skewing,
document slippage,
document feeding.
This error is generated if on two inserts

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

Error
Message
Cause
Information
INS-JOB000
Empty feeders
Empty feeders, wrong

document type, document
width setting, manual
document separation
adjustment.
This error is generated if all feeders are

empty during the loadn Go scanning
session.
INS-JOB200
MaxiFeederTM
failure
Incorrect job settings for

maxiFeeder.
This error is generated if an MF is

plugged in and a job is started that does
not comply with the specifications of the
MF-3. This can occur when the lowest
feeder is a complete station, and the
document length is adjusted to >156
mm and/or to multifeed.
INS-JOB201
Unauthorized job
Incorrect document job

settings, dongle reading
failure.
This error is generated if a 2 station

machine is reconstructed to a 1.5
station machine (dongle removed) and
a job is started that does not comply
with the specifications for a half station.
This is the case when the document
length for that half station is adjusted to
>156 mm and/or to multifeed.
INS-JOB202
MaxiFeederTM
failure
Refer to INS-JOB-200.
Refer to INS-JOB-200.
INS-JOB300
not possible
Not supported documents

and envelope type detected
for loadn Go.
This error is generated when due to

folder limitations the fold can not be
made that was calculated based on
measured document lengths and
envelope height.
6-10
rev. 1.0 - 12/2009
Service Manual
075.1
6.3.14 Level detector errors (LD)

Error
Message
Cause
Information
INS-LD1200
Sealing risk
Low level sealing liquid.

The sealing liquid level is between 1 and
Envelopes may not be closed 6 mm.
properly.
INS-LD1400
Sealing reservoir is
not detected
Insert reservoir.
6.3.15 License errors (LIC)

Error
Message
Cause
INS-LIC200
Invalid license key

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

key for other machine.
license key (via supervisor menu) could
not be recognized or translated into a
valid option by the system. This error
can also be generated when the factory
license key could not be recognized or
translated to a set of valid options.
INS-LIC400
Update options
failed
ID/Option memory defect.
This error is generated if the addition of

an option into the option memory fails,
because the encrypted contents of the
ID tag does not match what is expected.
INS-LIC401
Option memory
failure
Option memory defect or

general hardware defect.
This error is generated if the ID tag is

not seen during power up. Reason can
be that option wiring is not connected or
that there is something wrong with the
hardware.
INS-LIC402
Option memory
failure
ID memory empty, wiring

defect, ID/Option memory
defect.
This error is generated if the ID tag

could not be read, both the system ID
or the options. Also when the system
code is not valid (depends on the
alphabet characters in the system ID).
This error will occur every time the
system is started, and the system can
function without the options.
INS-LIC403
Invalid data in
option memory/ID
tag
The option data in the tag is

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

license key (via supervisor menu) could
not be recognized or translated into a
valid option by the machine.
rev. 1.0 - 12/2009
Information
6-11
075.1
Service Manual
6.3.16 Motor errors (M)

Error
Message
Cause
Information
INS-M03400
Technical failure
Blockage of collator, collator This error is generated if the DC motor

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

Error
Message
Cause
INS-MOD200
OLS dialling
interrupted by user
The user/supervisor pressed OLS message: at the initiation of a new

the disconnect button while OLS connection and the drilling is
dialing out.
interrupted by user.
INS-MOD300
No dial tone
The modem failed to detect a

dial signal. Could also
happen if the phone line is
not connected.
OLS message: at Osiris connection set

up.
Check the phone line (e.g. by
connecting a normal analogue phone
and listening to the receiver. If there is a
Dalton, try disabling the dial tone detect
in the OLS configuration screen on the
device).
INS-MOD301
OLS dialling
interrupted
unexpectedly
INS-MOD302
OLS line busy
The phone number being

dialed is busy.
OLS message: at the initiation of a new

OLS connection and there is no
incoming phone line available at the
server or there is congestion on the
public phone network. Try again later
INS-MOD303
No carrier
The modem failed to

OLS message: at the initiation of a new
negotiate with the modem of OLS connection. This could have
the server.
multiple reasons. E.g. the quality of the
line is bad or the negotiation with the
modem of the server failed. Try again
later. If it continues to fail repeatedly
verify line signal quality for example by
connecting an analogue phone to the
line and listen to the dial tone, try to
make an external call.
6-12
Information
rev. 1.0 - 12/2009
Service Manual
075.1
Error
Message
Cause
Information
INS-MOD400
Technical failure
Modem not ready or serial

port initialization of modem
failed.
OLS error at IN startup and

configuration check (only when OLS is
switched on in service menu).
INS-MOD401
No analogue phone
detected
There is no analogue phone OLS message: at Osiris connection set

line connected to the
up.
machine or the line is faulty. Check the phone line.
INS-MOD580
Technical failure
No modem available/
detected, modem defect,
modem not plugged in, cable
defect, no connector board,
connector board defect.
rev. 1.0 - 12/2009
OLS error. At IN startup and

configuration check and modem is
expected because of service settings or
licence.
6-13
075.1
Service Manual
6.3.18 Online service errors (OLS)

Error
Message
Cause
Information
INS-OLS000
New online service

messages
New OLS message on

communication board.
OLS message. At start up of system

when OLS is enabled and new messages
are available in OLS menu.
INS-OLS300
OLS server not

responding
INS-OLS301
OLS server not

ready
INS-OLS302
OLS connection
refused by server
At setting up an OLS
connection the
authentication process of the
system failed because
system is not allowed to
connect.
OLS message: the IP settings are not

correct.
Check IP number and port. Also it could
be possible that the device is not
allowed to authenticating.
INS-OLS303
Protocol error
The connection to the server

succeeded but the server
doesn't allow this device to
communicate with the
server.
OLS message: the device is not known

by the server. Check on the OLS server
if this device serial number is known by
the server.
INS-OLS304
OLS connecting to
server failed (timeout answer)
INS-OLS305
Low infrastructure
quality
INS-OLS306
Automatic stats
upload failed
The upload of statistics is

interrupted.
Ask OLS server administrator to

investigate.
INS-OLS307
Configuration
upload/download
failed
The upload of the

configuration information is
interrupted.

investigate.
INS-OLS308
Automatic software
download failed
A software download is
interrupted.

investigate.
INS-OLS309
Automatic job
download failed
A job download is
interrupted.

investigate.
INS-OLS310
Automatic feature
download failed
A feature download is
interrupted.

investigate.
INS-OLS311
Automatic flex code

download failed
A flex OMR download is

interrupted.

investigate.
INS-OLS312
Auto connection
failure
Automatic connection failed.

Statistic buffer overflow
>95%, batch data might be
lost.
OLS error. During operations, when stop

or clear is pressed and the system is
stopped, and allocated memory is
getting full. Only when OLS is on en
options statistics is enabled.
6-14
rev. 1.0 - 12/2009
Service Manual
075.1
6.3.19 Reading head errors (OR)

Error
Message
Cause
Information
INS-OR1400
Technical failure
Reading head dirty, LED

defect, photocell defect,
cables defect.

LED in the reading head is defect.
6.3.20 Photocell errors (Pxx)

The coding of the photocells is as follows:
Photocell code
Reference photocell
P01
Envelope track sensor
P02
Envelope flap sensor
P03
Insert table sensor
P04
Exit sensor
P05
Closer sensor
P06
Folder entry sensor
P07
Vertical track sensor
P08
Collator entry sensor
P09
Feeder sensor
P10
Feeder sensor
P11
Feeder sensor
The error list below covers all photocell errors.

Note
The error numbers can be different for some photocells.
rev. 1.0 - 12/2009
6-15
075.1
Service Manual
Error
Message
Cause
Information
INS-Pxx300
Photocell dusty
Low voltage received by the

photocell (dusty).
Dust error.
This error is generated if the DAC
current becomes too high during
operation. You are warned if the DAC
current increases and the sensor power
decreases (< 0,8 V). This error is
generated each 25 docs.
After pressing the reset button, the
following warning message appears:
1 Remove paper at sensor position
2 Clean sensor with bellow or brush
3 Press OK to reset sensor
SK4: The involved photocell values are
reset.
Go back to the main menu.
INS-Pxx300
Sensor error
Too much voltage received

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

This error is generated if the involved
photocell is too sensitive: during
adjustment the LED current becomes
too low (adjustment after 25 sheets).
Lower limit is 5/256 x100%.
After pressing the reset button, the
following warning message appears:
reset.
Go back to the main menu.
INS-Pxx302
Technical failure
LED current adjusted too

low. Photocell sensor adjust
error
Photocell adjust error.

photocell can not be adjusted correctly.
The DAC current is too low (<5/256
X100%). Only when the system is
started the first time or when the
system is adjusted again after a dusty
error.
After a reset, the error message
disappears. If the particular photocell is
not needed for the selected job, the job
can still be carried out. If the photocell
is needed or if a new job is selected, the
error appears again as soon as the start
button is pressed or a test run is
performed.
6-16
rev. 1.0 - 12/2009
Service Manual
075.1
Error
Message
Cause
Information
INS-Pxx302
Sensor error
Voltage received by the

photocell is too high due to
dust fall off
Dust error. This error is generated if the

voltage in the involved photocell
receiver suddenly increases significantly
(e.g. by dust that falls off). Danger
arises that the voltage in de receiver (>
1,5 V) stays too high when paper is
present. After pressing the reset button,
the following warning message appears:
reset. Go back to the main menu.
INS-Pxx303
Technical failure
Sensor adjust error. Led

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

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.
performed.
INS-Pxx401
Technical failure
Sensor defective. Photocell, Power up photocell detection error.

cables or connectors defect. This error is generated if no LED current
is detected in the involved photocell
(LED incorrect or not connected) during
powering up the system.
performed.
rev. 1.0 - 12/2009
6-17
075.1
Service Manual
6.3.21 PCB errors (PBx)

Error
Message
Cause
Information
INS-PB1300
Technical failure
FRAM chip contains old data System error. This error is generated
structure.
during starting up of the machine.
INS-PB1301
Technical failure
FRAM chip contains corrupt

data.
System error. This error is generated

during reading of a data block.
INS-PB1402
Technical failure
FRAM chip is not available.
System error. This error is generated

during starting up or operation of the
machine.
INS-PB1403
Technical failure
FRAM chip is not formatted.

the machine is started up (at least) the
first time.
INS-PB1404
Technical failure
Communication failure
INS-PB2301
Technical failure
FRAM not formatted.
During start up, and OLS/FIF is enabled.
INS-PB2301
Technical failure
FRAM contains old data

structure.
During start up, and OLS/FIF is enabled
INS-PB2301
Technical failure
FRAM contains corrupt data. When reading data block
INS-PB2400
Technical failure
Clock update received from

server failed.
During run, system should continue.
INS-PB2406
Technical failure
Internal cables defect or

communication/connection
board defect.
INF error. At IN startup and

configuration check (only when INF
options are enabled). Also when INF job
is started or INF job is edited and no
communication is possible.
INS-PB2407
Technical failure
FRAM chip not available on

During start up, and OLS/FIF is enabled.
INS-PB2408
Technical failure
PCB communication board

failure.
During start up of the system (and OLS/

FIF is enabled).
6.3.22 Pulse disc errors (PD)

Error
Message
Cause
INS-PD1400
Technical failure
Main motor defect, pulse disc System error. This error is generated if
defect, cables defect.
the pulse disk of the main power does
not generate enough pulses or if the
width of the pulses is irregular. The
motor is too heavily loaded or the pulse
disk is defect. For the boundaries, refer
to the pulse disk test in the service
menu.
6-18
Information
rev. 1.0 - 12/2009
Service Manual
075.1
6.3.23 Production control errors (PRC)

Error
Message
Cause
Information
INS-PRC000
Automatic clear of
system
Special clear for documents
Remove documents from collator.
INS-PRC290
Unexpected
documents in
system
System not cleared after job This error is generated if documents are
change
still in the system after a change of
jobs. This can be prevented by ending a
job with emptying the system, before
changing jobs.
6.3.24 Reading errors (RE)

Error
Message
Cause
Information
INS-RE1000
Reading stop
Stop mark read.
OMR error. Remove the set and press

Reset. A complete set is on the collator
and must be handled manually.
INS-RE1003
Suspected set
Incomplete sets collected

after reading error.
OMR error. This error is generated after

an earlier appeared reading error. The
paper run command insert is read.
The earlier appeared reading error
probably occurred halfway a set,
because of which that set and the next
one are incomplete.
INS-RE1003
Final set part
Incorrect marks read,

reading job settings.

remains of the set (until the insert sign)
are collated after removing an
incomplete set and pressing Reset and
Start for error INS-RE1-312. If again
the maximum amount of sheets in a set
is exceeded, error INS-RE1-312 is
generated again.
INS-RE1300
Wrong reading
window position
Incorrect reading job

settings.
OMR error. This error is generated when

the reading window is behind the end of
the paper.
INS-RE1302
Reading error
Less marks read than

expected.
OMR error. This error is generated if less

reading code marks are seen, than
possible with the chosen reading code.
The set can - but does not need to - be
taken out of the collator. After a restart,
the rest of the set is finished, after
which error INS-RE1-003 shows.
INS-RE1303
Reading error
More than 1 basic command OMR error. This error is generated if

(accumulate/ insert/ divert/ more paper running assignments are
stop mark) read.
readable in the bar code. The set can but does not need to - be taken out of
the collator. After a restart, the rest of
the set is finished, after which error
INS-RE1-003 shows.
rev. 1.0 - 12/2009
6-19
075.1
Service Manual
Error
Message
Cause
Information
INS-RE1304
Reading error
No basic command
(accumulate/ insert/ divert/
stop/ start/ safety mark)
read.
OMR error. This error is generated if no

barcode line that indicates the paper run
(accumulate/ insert/ divert/ stop mark)
is found. Start and safety mark
included. The set can - but does not
need to - be taken out of the collator.
After a restart, the rest of the set is
finished, after which error INS-RE1-003
shows.
INS-RE1305
Reading error
Matching varies within the

set.
OMR error. This error is generated if one

sheet within a set has another match
number (only with Flex code). The set
can - but does not need to - be taken
out of the collator. After a restart, the
rest of the set is finished, after which
error INS-RE1-003 shows.
INS-RE1306
Reading error
Sequence number of
document does not match
with previous document.

order, as guarded by the sequence
numbering of the documents, is no
longer correct. The set can - but does
not need to - be taken out of the
collator. After a restart, the rest of the
set is finished, after which error INSRE1-003 shows.
INS-RE1307
Reading error
Matching number of set is

not correct (related to
previous set).

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
INS-RE1308
Reading error
Parity of the marks read is

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

parity of a read code is incorrect. The
set can - but does not need to - be
INS-RE1309
Reading error
A mark is read at an illegal

position.
OMR error. This error code is generated

when a barcode line is read that can not
be in that particular position (too many
lines or inconsistent with other lines).
The set can - but does not need to - be
6-20
rev. 1.0 - 12/2009
Service Manual
075.1
Error
Message
Cause
Information
INS-RE1310
Reading error

reading job settings,
slippage, reading head
adjustments needed.

position of a barcode line is moved that
far, that it has arrived in the so called
forbidden zone. (The forbidden zone is
an area halfway two lines, that is
defined as a percentage of the line
distance.) The set can - but does not
shows.
INS-RE1311
Reading error

OMR error. This error is generated if
reading job settings, reading more barcode lines are present than
window too long.
allowed for the used barcode (only for
OMR level 0). The set can - but does not
shows.
INS-RE1312
Too many
documents
Set size exceeds maximum

number from reading job
settings, incorrect marks
read.
OMR error. Remove the set and press

Reset. To restart the system, press
Start. During collating through reading,
a set should always be completed.
However, a maximum set size is
indicated in the OMR setting menu
(attachments are included). When this
maximum size is reached, the collating
stops and this error is generated. This
does not happen during overlapping
supply from the feeders.
INS-RE1313
Reading error
No safety mark read.

a safety mark is not read. The set may
be removed from the collator. Pressing
Reset and Start will result in error INSRE1-003 Suspected set.
INS-RE1314
Reading error
Group start mark error.

a group start mark is not read. The set
may be removed from the collator.
Pressing Reset and Start will result in
error INS-RE1-003 Suspected set.
INS-RE1315
Reading error
Group end mark error.

a group end mark is not read. The set
may be removed from the collator.
Pressing Reset and Start will result in
error INS-RE1-003 Suspected set.
INS-RE1321
Reading error
The barcode could not be

read correctly.
Remove documents.
INS-RE1322
Reading error
The barcode is too long.
Remove documents.
rev. 1.0 - 12/2009
6-21
075.1
Service Manual
Error
Message
Cause
Information
INS-RE1323
Reading error
The barcode is too short.
Remove documents.
INS-RE1324
Reading error
Wrong start of set.
The new set does not start with N=1.

Remove documents.
INS-RE1325
Reading error
Sequence error.
N is not one more than the previous N in

the same set. Reset & start to finish set.
INS-RE1326
Reading error
M cannot be 0.
Remove documents.
INS-RE1327
Reading error
M changed in set.
Remove documents.
6.3.25 Machine state errors (SM)

Error
Message
Cause
Information
INS-SM1301
Envelope stoppage
Envelope lost in envelope

track.
Remove envelope.
INS-SM4301
Document transport Document transport failure.

failure
Remove documents check exit.
6.3.26 Stacker errors (STK)

Error
Message
Cause
Information
INS-STK000
Stacker almost full
About 10 envelopes to go
before message INS_STK001 appears.
Remove envelopes from stacker.
INS-STK100
Envelope stoppage
Unexpected mail set in

stacker transport path.
Time between the detection of the end

of the envelope at the inserter exit and
detection by the stacker sensor is too
long.
INS-STK101
Envelope stoppage
Stacker sensor covered too

long.
Remove all documents, check exit.
INS-STK300
Stacker full
Remove envelopes from

stacker.
INS-STK301
Envelope stoppage
Envelope too early at

stacker.
INS-STK400
Stacker Failure
Stacker cycle not finished in The photocell in the stack unit detects
time.
that the stacker cycle takes more than
0.75 s.
Remove all mail sets and check stacker.
6-22
Stacker is still busy when the envelope

arrives at the stacker sensor. Remove all
documents, check exit.
rev. 1.0 - 12/2009
Service Manual
075.1
6.3.27 Switches errors (SW)

Error
Message
Cause
Information
INS-SW1200
Cover open
Front cover open, cover

switches defect or loose,
envelope track sensors.
This error is generated if during a run

the front cover is opened.
INS-SW2200
Cover open
Collator cover open, cover


the collator cover is opened.
INS-SW3200
Cover open
Top cover open, cover


the top cover is opened.
INS-SW4200
Cover open
Stacker cover open, cover


the HCVS-1 cover is opened.
Cause
Information
6.3.28 System errors (SYS)

Error
Message
INS-SYS000
Preventive
Total counter equal to
maintenance needed Service Counter, Service
counter incorrect.
This error is generated if the next visit

service counter value is reached. The
message will appear at system start.
INS-SYS200
Serial number
already present in
ID tag
Machine's software and

identity are setup already.
This error is generated if a machine is

prepared in the factory and later on an
attempt is made to prepare the machine
again. Preparation (flashing and setting
serial number) should only be done on
pristine machines.
INS-SYS300
Technical failure
Connection board restarted. Reset to continue.
INS-SYS304
Technical failure
Communication failure
between inserter and
INS-SYS501
Illegal configuration Illegal configuration

detected.
rev. 1.0 - 12/2009
Reset to continue.
This error is generated when the serial

number in the ID-tag 2994504Z does
not match the serial number in the Fram
of the main board. The machine is
blocked from operating, because the
counters in the Fram and the ID-tag
2994504Z do not match. See 4.3.9
Remove blockage on page 4-15.
6-23
075.1
Service Manual
Error
Message
Cause
Information
INS-SYS563
Technical failure
Incorrect software in
communication board or
inserter board.
At IN startup and configuration check.

Communication board is expected
because of service settings or licence.
INS-SYS580
Technical failure
System serial number

memorized in
communication board is not
the same as on ID tag. Most
likely because of exchanged
connection board from an
existing system.
OLS or INF error. At IN startup and

configuration check. Communication
board is configured on a different
inserter than the current inserter (based
on serial number). After reset error:
choose Continue without action or
Initialise communication board.
INS-SYS581
Technical failure
Communication board
OLS or INF error. At IN startup and
missing or defect, or internal configuration check. Also when INF info
cables or PCB defect.
is needed (INF job start, INF job
adjust). Communication board is
licence. Cause: internal Cables, PCB
defect.
INS-SYS582
Technical failure
The installed modem could

not be detected as a legal
version.
OLS error. At IN startup and

configuration check a modem is
licence.
6.3.29 Transport errors (TR)

Error
Message
INS-TR2110
Document transport Document path blockage,

failure
slippage, vertical track
photocells dusty.
This error is generated if the document

does not arrive in time at the collator
entry cell (if transport time between
leaving feeder and arriving at folder
entry exceeds 700 mm (750 pulses)).
INS-TR2290
Unexpected
documents in
vertical track
Document stoppage at
vertical track photocell.
Remove documents.
INS-TR3120
Envelope stoppage
Blocked envelope path,

slippage.
This error is generated if the envelope

or document transport from insert area
to closer sensor would take too long.
Longer than the time that meets 1200
flanks (approx. 600 mm).
INS-TR4110
Envelope stoppage
Transport failure between

envelope closing and
envelope exit.
INS-TR4120
Envelope stoppage
at exit
Blockage at envelope exit,

inserting failure, skewing,
slippage, exit blockage.
6-24
Cause
Information
This error is generated if the exit

detector is covered longer than 300 ms.
rev. 1.0 - 12/2009
Service Manual
6.4
075.1
Error handling franking machine
After pressing the i button in an error message screen, the display can show an error code.
The error format for franking machine errors is as follows: FRM-XXX-YYY. The inserter messages
are explained in 6.3 Error handling inserter on page 6-2. XXX is an abbreviation that indicates
a specific machine part. The following machine areas/prefixes apply:
XXX
Explanation
Reference
COM
Communication
6.4.1 Communication errors (COM) on page 6-26
EX
External
6.4.2 External errors (EX) on page 6-26
INF
insertn Frank
6.4.3 Insertn Frank errors (INF) on page 6-27
LIC
License
6.4.4 License errors (LIC) on page 6-34
SW
Cover switches
6.4.5 Cover switch errors (SW) on page 6-34
rev. 1.0 - 12/2009
6-25
075.1
6.4.1
Service Manual
Communication errors (COM)
Error
Message
Cause
Information
FRM-COM920
No communication
with franking
machine
Due to a time out INF

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

which information from FM is needed),
job info or starting DS+MS job. In job
edit, after reset: continue the job edit
menu. The fields you cannot adjust and
knobs that belong to these fields are
grey. You can only select pass
through.
FRM-COM921
Communication
Indicates that the FM won't When pressing start key.
failure with franking accept commands and/or
machine
data from INF. Just wait and
try to start the job again or
switch off/on the FM.
FRM-COM922
Communication
Due to some fatal error
When pressing start key.
failure with franking conditions, communication
machine
with the FM has dropped in
Alayer. Try to start the job
again or switch off/on the FM
or the whole system.
FRM-COM923

Communication
machine
Tlayer. Try to start the job
FRM-COM924
Communication
machine
Dlayer. Try to start the job
6.4.2
External errors (EX)
Error
Message
Cause
FRM-EX1120
Envelope stoppage
between inserter
and franking
machine
This error is raised when an During run

envelope is not franked
within X seconds after
leaving the inserter. The X is
system and configuration
dependent. The envelope
might not be franked by the
FM.
6-26
Information
rev. 1.0 - 12/2009
Service Manual
6.4.3
075.1
Insertn Frank errors (INF)
Error
Message
Cause
FRM-INF000
Auto clean on
franking machine in
progress
Notification from the FM that When pressing start key.

the Auto Clean Cycle will be
started very soon.
FRM-INF001
Franking machine
not ready for
franking interface
At the FM is currently a
dialog displayed as a result
of an error (condition) that
occurred while INF was not
executing a job on the FM.
Probably the FM was used
stand alone. Look at the FM
user interface.
FRM-INF002
Auto clean on
franking machine is
finished
Notification from INF that

the Auto Clean Cycle has
been completed and the
franking process will be
resumed automatically.
FRM-INF003
Sealing on advanced An attempt is made to start

an FM job with sealing on
feeder of franking
machine is selected advanced feeder selected.
The user can only solve this
by modifying the FM job
(disable sealing) or
modifying the IN job.
FRM-INF200
Franking machine
already started
The FM cannot be started as When pressing start key.

it is already running.
Probably the user started the
FM manually or the FM was
not stopped in the previous
job. If not, switch off/on the
FM.
FRM-INF201
Franking machine
stopped via start/
stop key
This error is raised when the

user pressed the 'Stop'
button on the FM during a
run resulting in an
emergency stop. The last
envelopes(s) that left the
franking machine might not
be franked.
FRM-INF202
User PIN code

The FM has popped up a
required at franking dialog to enter the user PIN
machine
code. Job execution will be
blocked until the correct PIN
code has been entered.
rev. 1.0 - 12/2009
Information
6-27
075.1
Service Manual
Error
Message
Cause
FRM-INF203
Department PIN
code required at
franking machine
The FM job selected requires When pressing start key.

a department PIN code. INF
does not support this
feature. Job execution is
blocked. Either the PIN code
has to be removed or
another FM job has to be
selected.
FRM-INF204
Wrong PIN code

entered on franking
machine
The user has entered the

wrong PIN code and the FM
will go into 'sleep' mode. Job
execution is blocked.
FRM-INF205
User action required User action required at

at franking machine franking machine.
FRM-INF206
The franking
machine is in
supervisor mode
FRM-INF207
ZIP zone required at The FM has popped up a

franking machine
dialog to enter the ZIP Zone.
Job execution will be blocked
until a ZIP Zone has been
entered.
FRM-INF208
Franking machine
Franking interface software
job selected includes does not support this
correction mode
feature. Switch off correction
mode or select another
franking machine job
FRM-INF209
Franking machine
stopped via escape
key
FRM-INF210
Franking machine is The FM is being used 'stand

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

job info or starting DS+MS job. In job
edit, after reset: continue the job edit
menu. The fields you cannot adjust and
knobs that belong to these fields are
grey. You can only select pass
through.
FRM-INF300
Communication
A time-out occurred when
failure with franking attempting to wake up the
machine
FM from sleep/stand-by
mode. The FM did not wake
up in time. Try to start the
job again or switch off/on
the FM.
During run.
6-28
Information
See franking machine for more details.
An attempt is made to
execute a job while the FM is
in Supervisor mode. Exit
Supervisor mode at the FM
and try to start the job
again.
The user has aborted the

franking cycle by pressing
'ESCAPE' at the FM. The job
will be aborted.
rev. 1.0 - 12/2009
Service Manual
Error
Message
FRM-INF301
Due to an unsupported error When pressing start key.

Communication
failure with franking condition the FM refuses to
start. The user has to try to
machine
start the job from the IN
again. If this fails switch the
FM on/off.
FRM-INF302
An internal error
Due to an unsupported error During run or pressing start key.
occurred which
INF is unable to stop the FM.
blocks job execution Switch off/on the FM.
FRM-INF303
Communication
Due to an unsupported error During run.
failure with franking the FM did not complete the
machine
starting sequence in time.
Try to start the job again or
FRM-INF304
The franking
machine is in error
mode
INF is not able to configure When pressing start key.

the FM as an error has
occurred that has not yet
been solved and is not
specified. Please check the
FM user interface for any
message and close any
covers. Otherwise switch off/
on the FM.
FRM-INF305
The franking
machine is in busy
mode
INF is not able to configure When pressing start key.

the FM as the FM is busy for
some unknown reason.
Please wait a while,
otherwise switch off/on the
FM.
FRM-INF305
An internal error
For some reason the FM is
occurred which
busy and won't accept
blocks job execution commands from INF.
Possibly the FM was
manually started by the user.
Otherwise switch the FM off/
on.
FRM-INF306
Auto clean on
franking machine
time out
Notification from INF that

the Auto Clean Cycle takes
more time than expected.
Either the user wait until the
FM has actually finished Auto
Clean or switch the FM off/
on.
FRM-INF307
No active rate table
No active rate table,

probably Base only, activate
rate table.
rev. 1.0 - 12/2009
Cause
075.1
Information
6-29
075.1
Service Manual
Error
Message
Cause
Information
FRM-INF308
Internal error on
franking machine
The FM decided to execute

an emergency stop.
However, it did not provide
any further information for
the reason. Try to start the
job again or switch off/on
the FM.
During run or pressing start key.
FRM-INF309
Manual clean of
An attempt to force to clean When pressing start key.
cartridge on franking the cartridge manually
machine failed
failed. Not user solvable! Try
again.
FRM-INF310
More envelopes
have been franked
than sent by the
inserter system
Possible presence of
envelopes in FM from
previous job, or envelopes
manually put onto the FM
during the job.
FRM-INF311
Selecting franking
machine job failed
Unable to select a job at the During run or pressing start key.

FM due to an unsupported
error. Try to restart the job
again or switch off/on the
FM.
FRM-INF312
Selecting franking
machine job failed
Inserter job is coupled to a

non-existing FM job (the
specified job ID is empty).
Update the job definition at
the IN or create a job at the
FM.
FRM-INF313
Wait position
occupied
INF received data for the

next envelope while the
current envelope has not yet
left the waiting position.
Restart the job.
FRM-INF314
Franking machine
job selected includes
Dynamic batch
mode
An attempt is made to start When pressing start key.

an FM job from the IN. The
FM job includes Dynamic
Batch Mode which is not
supported when KEOPS is in
Inserter Mode. This job is
blocked by INF. Either the
user has to switch off
Dynamic Batch Mode or
has to select another job.
FRM-INF315
The franking value

exceeded the 'High
value threshold
A job was started in which

the franking value exceeded
the 'High value' threshold.
The user has to confirm this
high value at the FM by
either pressing 'OK' or
'ESCAPE'.
6-30
During run.

starting DS+MS job. In job edit, after
reset: continue the job edit menu. The
fields you cannot adjust and knobs that
belong to these fields are grey. You can
only select pass through.
rev. 1.0 - 12/2009
Service Manual
Error
Message
FRM-INF315
Weight exceeds limit Check weight values in job

settings.
FRM-INF316
Envelope measures
FRM-INF317
Concerns incorrect set up of When pressing start key.

An internal error
the option. An attempt was
occurred which
blocks job execution made to set the franking
mode to an invalid or no
longer supported mode. As a
result the current franking
mode is retained. Probably
caused by incompatible
software versions of Inserter
and INF module.
FRM-INF318
Sealing on advanced An attempt is made to start It is recommended to seal with the

feeder of franking
an FM job with sealing on the inserter. This warning is generated when
machine is selected MMF/AF selected. This can
pressing the start key.
be overruled through the
service menu setting. See
4.3.10 Sealing on franking
machine on page 4-15.
FRM-INF900
Internal error on
franking machine
At the FM an error has

occurred that permanently
blocks execution of the
current run. The user has to
look at the UI of the FM for
more details. Best case, the
job can be started again
after resolving the problem.
Worst case the FM has to be
switched off/on.
FRM-INF901
Error or warning on
franking machine
At the FM an error has

occurred that temporarily
blocks execution of the
current run. The user has to
look at the UI of the FM for
more details. After solving
the problem, the run will be
resumed automatically.
FRM-INF902
Communication
INF received incorrect
failure with franking envelope data (unknown
machine
hopper or invalid hopper
data). Remove any
envelopes from the system
again.
rev. 1.0 - 12/2009
Cause
075.1
Information
Invalid envelope measure for When pressing start key.

PPC management.
6-31
075.1
Service Manual
Error
Message
FRM-INF903
INF received incorrect

Communication
failure with franking envelope data (unknown
thickness or invalid thickness
machine
data). Remove any
envelopes from the system
again.
FRM-INF904
An internal error
Unable to make some
During run.
occurred which
settings at the FM due to an
blocks job execution unsupported error. Try to
restart the job again or
FRM-INF905
An internal error
Unable to retrieve settings
occurred which
from the FM due to an
During run.
FRM-INF906
An internal error
Unable to configure the
occurred which
'Base' (FM) due to an
FRM-INF907
An internal error
occurred which
'Advanced Feeder' (AF) due
blocks job execution to an unsupported error. Try
to restart the job again or
FRM-INF908
Internal failure on
franking machine
FRM-INF909
Communication
The FM did not complete the When pressing start key.
failure with franking stop sequence in time. The
machine
FM might have to be
switched off/on in order to
continue with another job.
FRM-INF910
Communication
During job execution the FM When pressing start key.
failure with franking terminated the job
machine
unexpectedly for some
unknown reason. Try to
6-32
Cause
Information

'Dynamic Scale' (DS) due to
an unsupported error. Try to
rev. 1.0 - 12/2009
Service Manual
Error
Message
Cause
FRM-INF911
Communication
failure
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.
FRM-INF912
Unknown envelope
detected
INF has detected a physical When pressing start key.

envelop at the wait position,
but did not receive any data
for it. The envelope (if any)
has to be removed.
FRM-INF913
Unknown envelope
detected
INF has detected a physical When pressing start key.

envelop at the wait position,
but was not notified about its
arrival. The envelope (if any)
has to be removed.
FRM-INF914
An internal error
INF is busy and cannot
occurred which
accept any commands. An
blocks job execution attempt was made to change
settings while INF is busy.
Internal error, not user
solvable. Just try again later
and ultimately switch off/on
the whole system.
FRM-INF915
FIFO Overflow
FIFO Overflow for PPC

variable mode.
FRM-INF916
Rate calculation
Rate calculation failure.
075.1
rev. 1.0 - 12/2009
Information
6-33
075.1
6.4.4
Service Manual
License errors (LIC)
Error
Message
FRM-LIC300
An internal error
Concerns incorrect set up of When pressing start key.
occurred which
the option. The INF level is
blocks job execution set to INF_LEVEL_NO_INF.
Probably caused by
incompatible software
versions of Inserter and INF
module. Internal error, not
user solvable.
6.4.5
Cause
Information
Cover switch errors (SW)
Error
Message
Cause
Information
FRM-SW5200
Cover open on
franking machine
Franking machine cover

open, cover switches defect
or loose? Close the cover.
This error is only generated
when the cover switch is
activated. It does not
register if the cover is open
or closed.
6-34
rev. 1.0 - 12/2009
Service Manual
7
Upgrading and installing accessories
7.1
075.1
Reading (barcode en OMR)
See separate document: Mounting instruction no. 73.
7.2
MaxiFeeder
7.3
Insertn Frank
See separate documents: Mounting instructions no. 84, 85 and 109.
7.4
Side exit
7.5
See 10.5 High Capacity Vertical Stacker on page 10-43 and separate document: Mounting
instruction no. 113.
7.6
Mail Piece Production Control (MPPC)
7.7
Online services
See the procedure below and the separate mounting instruction: MI97 Communication
package.
This section describes how to connect an OLS machine in the field to the server.
7.7.1
Preparations
Check that following preparations are done before installing an OLS machine in the field.
1
2
3
4
The back office team has prepared the system for declaration on the server. The system
has the status allocated on the OpCoweb.
The system is OLS compatible. This means that the system is equipped with the connectivity
hardware:
communication board
connection board with modem
telephone cable
OLS is enabled on the system: from the Main menu, select Supervisor menu (pin 4351),
Total system, System settings, Configuration, Edit. Check if Online Services is
enabled.
A analogue telephone line is available.
rev. 1.0 - 12/2009
7-1
075.1
7.7.2
Service Manual
Connect the system
To connect the system, set the online service parameters.

1
From the Main menu, select Supervisor menu (Pin 2546), Online Services,
Configuration.
Note: Do not change the Dial tone detection, the Phone number and the Country.
These items are predefined.
2
Ask the customer if a prefix is necessary to dial to an external number. If that is necessary
enter the prefix.
Go to the second Configuration menu.
4
5
Set the date to the actual date.

Set the time to the actual time.
Note: Do not change the Modem volume. The modem volume is predefined.
6
Press the OK button.
Now the system is ready for initial declaration:

1
2
Connection, Connect.
The initial declaration call is finished if the connection status displays Disconnected.
Press the i button to see the status of the system.
System status: pending declaration if initial declaration was successful.
System status: undeclared if initial declaration has failed (see 6.2 Troubleshooting
Online Services on page 6-2).
Now the system is ready for declaration and for transferring data:
1
Connection, Connect.
The declaration call is finished if the connection status displays Disconnected.
7-2
rev. 1.0 - 12/2009
Service Manual
075.1
Press i button to see the status of the system.

System status: declared if declaration was successful. The machine is acknowledged
by the server.
System status: pending declaration if the machine is waiting to be declared or
declaration has failed (see 6.2 Troubleshooting Online Services on page 6-2).
If the machine status is undeclared the machine is not acknowledged by the server. The initial
declaration has failed.
rev. 1.0 - 12/2009
7-3
075.1
7-4
Service Manual
rev. 1.0 - 12/2009
Service Manual
8
Technical specifications
8.1
075.1
Machine specifications
Model:
075.1, M5500, Carat
Max, FPi 4500, FD6304
Type:
Fold and insert system for medium office use
Noise level:
< 66 dB(A) (according to ISO 11202)
Power consumption:
100V AC / 50 Hz / 5.0 Amps (voltage tolerance: +6%/-10%)

Processor:
32 bits ARM7
Memory:
16 Mb SDRAM and 4 Mb flash ROM
Approvals:
EMC Certificate conform EMC-Directive

FCC Certificate conform 47CFR, part 15
CB Certificate conform IEC 60950-1
UL Listed I.T.E. (Information Technology Equipment), conform
UL-IEC 60950-1, file E153801
Conform NEN-EN-IEC 60950-1 and derivatives
rev. 1.0 - 12/2009
8-1
075.1
Service Manual
Available models:
DS-75 Expert
3 standard feeders
DS-75 Special
2 standard feeders
1 special feeder at the bottom
DS-75 Expert + High Capacity (Document) Feeder 1 standard feeder

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

DS-75 High Capacity Expert
1 standard feeder
1 high capacity vertical stacker
DS-75 High Capacity Special
1 special feeder
DS-75 Max Capacity

1 high capacity BRE/insert feeder (MF-2)
About the standard (automatic) and special feeder:
Standard feeder: typically for normal address carrier documents from laser printers, impact
printers, copiers and also some glossy papers depending on a test
Special feeder: for special papers such as glossy papers, small booklets prefolded inserts,
but also for normal paper
8-2
rev. 1.0 - 12/2009
Service Manual
8.2
075.1
Documents
Paper length:
minimum
130 mm
140 mm
maximum (no fold, no insert)
242 mm
maximum (no fold)
236 mm
maximum with fold
230 mm
minimum
60 gr/m2
maximum without folding:
250 gr/m2
maximum with fold
Brochures:
356 mm (14")
minimum maxiFeederTM
Paper weight:
90 mm
maximum
Paper width:
minimum
170 gr/m2
maximum thickness (no fold)
1 mm
if flexible and back/fold leading into feeder
Reply envelopes:
80 gr/m2
minimum size
90x130 mm (height x width),

with MF-2: 90x140
maximum size
Set thickness:
minimum weight
156x236 mm (height x width)
Max. number of sheets to be folded:

10 x 80 gr/m2 (single fold)
8 x 80 gr/m2 (letter fold, Z-fold)
4 x 80 gr/m2 (double parallel fold)
Max. set thickness to be conveyed through folder: 2.5 mm
Max. number short documents not to be folded is 25 sheet of 80 gr/m2.
Depending on paper quality this is limited to 12-25 sheets of 80 gr/m2.
Max. thickness of a set after folding is: 2.5 mm
Note:
When sets are at maximum thickness (e.g. 7-8 sheets letter fold), it might be necessary to tune the fold
settings for good inserting and exit (especially side exit). For example, for A4: fold not 108/216 but 105/
210.
rev. 1.0 - 12/2009
8-3
075.1
Set height:
Service Manual
max.set height 156 mm (or envelope height -/-6)mm)

max set height (with not inserting) 203 mm [A], and mutual difference address
fold and set height/residual length max. 50 mm [B].
No fold:
Single fold:
Letter fold:
Z fold:
min. set height 84 mm

min. set height (with not inserting) 102 mm
Kinds of paper:
standard feeder
MC shiny up to and including mat
standard feeder
Recycled paper
8-4
Normal
standard feeder
rev. 1.0 - 12/2009
Service Manual
075.1
Booklets
standard feeder
Prefolded paper: A3 double to A4
special feeder
A4 folded to A5 or 4" or booklets
special feeder
Reply Envelopes
special feeder
Notes:
Powdered paper, NCR, satinated paper will not be able to achieve the reliability of the standard feeder.
Prefolded and reply envelopes can possibly be processed by the standard feeder. This should be tested
with each customer application.
8.3
Envelopes
Height:
minimum
90 mm
maximum
162 mm
maximum at presentation with open flap: Envelope + flap max. 165 mm
Width:
minimum
160 mm
minimum
Set width +12 mm with single sheet,

increasing to +28 mm for 8 sheet multiple
fold
maximum
248 mm
minimum
32 mm (in middle)
maximum
envelope height minus 32 mm
minimum
10 mm on 43 mm from the center
maximum
35 mm on 43 mm from the center
maximum dcollet in the center
75 mm
minimum paper weight:
80 gr/m2
maximum paper weight:
120 gr/m2
Flap height:
Dcollet:
Paper grade:
rev. 1.0 - 12/2009
8-5
075.1
Service Manual
Insert specifications
A
Minimum size
mm
160
90
32
10
130
84
60 g/m2
3.5
1.25
0.4
5.1
3.3
60 g/m2
inches 6.3
Maximum size
mm
248
inches 9.7
162
B-32
35
A-12**
B-6
2.5*
6.38
B-1.25
1.4
A-0.47**
B-0.2
0.1
* Booklets up to approximately 1 mm (0.04 inch) thickness, depending on stiffness

** When insert is more than 1 mm (0.04 inch): A-15 mm / A-0.6 inch
Notes
Maximum insert specifications are based on single sheets. When multiples are handled,
more room inside the envelope is needed depending on the application.
The specification of the paper handling equipment is often wider than that of the envelopes
and documents handled. The condition of material handled will limit the specified
environmental conditions.
We recommend that materials to be handled are stored at a temperature of 20C (68F)

with a relative humidity factor of 50%. If difference in temperature occurs between store
room and mailing area, the material has to be stored near the system at least 24 hours
before use.
Self-copying paper may cause rubber parts to wear quicker. The rubber used in this system
has the best resistance to Wiggins Teape material.
8.4
Capacity feeders and exit options
Capacity feeder hopper:
325 sheet 80 grm/m2, this is approximately 3.7 cm
Capacity high capacity feeder:
725 sheet 80 grm/m2, this is approximately 7.3 cm
Capacity BRE maxiFeederTM:
325 reply envelopes
Capacity envelope hopper:
160-170 mm (325 empty envelopes 80 gr/m2)
Capacity envelope exit options:

Catch tray
100 env C5/6 with 1xA4 80 gr/m2 multiple fold
Side exit catch tray
8-6
rev. 1.0 - 12/2009
Service Manual
8.5
075.1
Fold types
The 075.1 has two folding tables, both in upwards position seen from the paper path. The
following folds are possible:
No Fold
Single fold
Letter fold
Double parallel
Z fold
Feeding instructions:
Address/ Fold type
Z-fold
Other folds
Address carrier loaded in
Bottom station or Top station
Top station
Address face...
Down
Up
Address position
Trailing
Leading
Folding table limitations:

Maximum depth 1st folding table
255 mm
Maximum depth 2nd folding table
150 mm
Minimum depth in 1st and 2nd folding table
25 mm
Minimum distance from top of document to first

fold (address part)
Letter fold
75 mm
Maximum difference between 2 folds and the top

of document to first fold (address part)
Letter fold
105 mm
8.6
Processing speed
There are 3 fixed stop positions on the collator.

These positions are:
a: A5
b: A4
c: 14"
The actual stop position used depends on the set length of the current job, and will be
automatically activated:
When the set length is 148 or shorter stop, a will be used.
When the set length is 149 to 297 stop, b will be used.
When the set length is 298 to 356 stop, c will be used.
rev. 1.0 - 12/2009
8-7
075.1
Service Manual
System speed per job:

Feeder 3:
1xA4
Feeder 2:
1xA4
1xA4
3xA4
1xA4
2xA4
2xA4
Feeder 1:
1xA5
1x11"
1xA4
1x14"
1x100
1xA4
1xA4
1x100
1x100
Fold:
E 108
W 99/
198
W 108/
216
DP 99/
198
W 96/
204
W 108/
216
W 108/
216
W 106/
212
W
106/
212
Collator at:
Mode:
Doc offset:
50
50
50
50
50
50
50
50
50
BRE offset:
yes
yes
yes
yes
yes
yes
yes
yes
yes
Envelope:
C5/6
(114)
#10
(105)
C5/6
(114)
#10
(105)
C5/6
(114)
C5/6
(114)
C5/6
(114)
C5/6
(114)
C5/6
(114)
Output/hour:
3500
3060
3000
2500
2650
2650
2200
900
900
8.7
Configuration dimensions
Length:
770 mm
on covers
1120 mm
including hopper (90 mm) and feeder trays (265 mm)
1270 - 1360 mm
including standard exit (catch tray)
1200 mm
including side exit
1360 mm
including high capacity vertical stacker
Width:
455 mm
(the optional side exit is 90-195 mm outside side cover)
Height:
720 mm
800 mm
8.8
including high capacity vertical stacker
System operation control
Features
Performance
Number of jobs programmable
25
Screen size
20mm * 90 mm
Screen resolution
Resolution: 320 * 240 pixels
Screen technology
Full color touch screen
8-8
rev. 1.0 - 12/2009
Service Manual
8.9
075.1
Other general specifications
Features
Performance
Operating temperature
10C - 40C
Operating humidity
30% - 80%
Weight
Whole system: 73 kg
8.10
Quality
Maximum volume per month: 40,000 envelopes
8.11
Reading (Optical Mark Recognition)
8.11.1 Concept
One track OMR code

Factory fitted as well as field upgradeable
Available levels: Basic, Advanced and Flex
8.11.2 Format of the marks

Minimum character length: 6.3 mm or 3 characters.
8.11.3 Reading head location
The reading head is located in the vertical transport area between the first and second feeder.
That means that the 075.1 can read from feeder 2 and 3.
8.11.4 Options
Flexible OMR is also available on the 075.1.
Flexible OMR enables the customer to read the OMR codes of different suppliers. This means that
the system can comprehend and execute the command in the different codes of for instance
Pitney Bowes and/or PFE. The flexible OMR dongles can contain up to 9 different codes.
8.12
Reading (Barcode)
8.12.1 Concept
1D vertical bar code

Factory fitted as well as field upgradeable
Available levels: Basic, Advanced and Flex
8.12.2 Format of the code

The minimal height of the code is 9 mm (0.35 inch).
The minimal thickness of a bar in de code is 0.25 mm (0.01 inch).
8.12.3 Reading head location
The reading head is located in the vertical transport area between the first and second feeder.
That means that the 075.1 can read from feeder 2 and 3.
8.12.4 Options
Flexible BCR is also available on the 075.1.
rev. 1.0 - 12/2009
8-9
075.1
Service Manual
Flexible BCR enables the customer to read the BCR codes of different suppliers. This means that
the system can comprehend and execute the command in the different codes of for instance PFE.
8.13
Product customization per country / organization
There is no product customization per country specific to 075.1 except for the usual differences,
for example voltage and plugs.
The 075.1 will also be built under the product names: M5500, Carat
8-10
Max, FPi 4500, FD6304.
rev. 1.0 - 12/2009
Service Manual
9
075.1
Illustrated parts list
This section contains information on the available spare parts. Use the figures and
accompanying tables in this section to find the appropriate part numbers.
Note
Each figure has its own title. Therefore, to quickly find the figure you need, you can refer to the
Table of Contents at the front of this manual.
rev. 1.0 - 12/2009
9-1
075.1
9.1
9-2
Service Manual
Covers, frames, and external parts 1/3
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
Part number Quantity
1
2
3
4
5
6
Cover plate LH (lower)

Round head screw M4 x 8
Strip
Washer 12x5.2x0.7mm
Bellows
User's guide
2825411L
2054313J
2970051C
2430535G
2041304H
2894393S
1
1
1
2
1
1
2894394T
2894395U
2894396V
2894397W
Grommet
Hinge bracket
Screening plate
Magnetic clip
Countersunk head screw m4x10
Decorative cover LH
Decorative cover RH
Round head tapping screw
Round head screw m4x10
Cover plate RH (lower)
Nut m4
Self-locking clip
Hex. head screw M4x8
Front cover tower 3 st.
2120851U
2994060M
2964613N
2957091C
2053875C
2994066T
2994068V
2453858B
2454314B
2453868M
2825412M
2451902P
2052602B
2053880H
2825428D
2825456H
1
1
1
2
2
1
1
2
2
10
1
8
2
5
1
1

Front cover tower HCF
2825457J
2825439Q
2825458K
1
1
1

Front cover LH
Front cover LH
Front cover LH
Front cover LH
Front cover LH
Front cover LH
Reinforcement plate
Main board cover assy.
Magnet mounting plate
Sealing liquid tray
Envelope tray (assy.)
2825434K
2825440R
2825441S
2825442T
2825433J
2825435L
2825424Z
2994059L
2994027C
2994076D
2825250T
2989259L
1
1
1
1
1
1
1
1
1
1
1
1
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
rev. 1.0 - 12/2009
Remarks
Neopost brand,
EN-FR-ES
Neopost brand,
IT-FR-DE
Neopost brand,
FR-DE-NL
2nd channel
brand,
EN-FR-ES
2nd channel
brand,
EN-DE-NL
Neopost
Hasler, blank
Formax, Satas
Francotyp
Neopost
Hasler, blank
Formax, Satas
Francotyp
Neopost
Hasler
Formax
Satas
Francotyp
blank
9-3
075.1
Service Manual
Number
Description
28
29
Slide complete
Side cover RH
2042320R
2825413N
1
1
30
Side cover RH
Cover plate
2825423Y
2964612M
1
1
9-4
Remarks
Neopost,
Hasler, blank
Formax, Satas
Francotyp
rev. 1.0 - 12/2009
Service Manual
075.1
Intentionally blank
rev. 1.0 - 12/2009
9-5
075.1
9.2
9-6
Service Manual
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Bottom cover collator area

Cover dark edge LH
Cover dark edge RH
Top cover bracket
Nut m4
Stud
Float magnet
Sealing liquid tray
Moistening cloth
Sealing liquid sensor assy.
Clamping strip
Support plate
Bottom plate
Collator area cover
Top cover assy.
Power supply cover plate
Communication unit assy. (standard)
Communication unit assy. (extended)
Screwlock
2825403C
2825401A
2825402B
2825404D
2451902P
2053875C
2989219U
2053880H
2825255Y
2825250T
2453869M
2040306T
2825246P
2043201J
2260452M
2989217S
2825419U
2825417S
2994020V
2994081J
2994079G
2994070X
rev. 1.0 - 12/2009
Remarks
1
1
1
2
8
3
3
7
1
1
17
1
1
6
1
1
1
1
1
1
1
1
9-7
075.1
9.3
9-8
Service Manual
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
Transparant plate
Top cover upper unit
Ejot screw 2,5 x 8
Loc cover
Nut m4
Screw 5.0x14
Round head screw M4x8
Vertical transport cover
Stop button assy.
Start button assy.
Reinforcement plate assy.
2994067U
2825400Z
2994088R
2994071Y
2053880H
2451902P
2989183G
2053868V
2453875U
2825405E
2825452D
2825451C
2994069W
rev. 1.0 - 12/2009
Remarks
1
1
1
1
4
2
4
3
2
1
1
1
1
9-9
075.1
9.4
9-10
Service Manual
Envelope hopper 1/2
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Washer 14x8,2x0,8mm
Side guide RH
Front plate RH
Flanged bush
Front plate LH
Countersunk head screw M4x10
Spring clip 7-9mm
O-ring
Flat spring
Thumb wheel
Side guide LH
Nut m4
Adjustment axle
Locking spring
Bottom cover
Pressure spring
Bracket for axle
Envelope support (assy.)
Feed table (assy.)
Front plate (assy.)
2040141W
2825445W
2994355U
2053866T
2994379U
2994354T
2994375Q
2052442K
2994376R
2994374P
2241358X
2825444V
2451902P
2994372M
2036336H
2994363C
2043091U
2053875C
2454211U
2994373N
2053871Y
2825447Y
2825443U
2809106B
rev. 1.0 - 12/2009
Remarks
1
1
1
10
2
1
1
1
1
2
1
1
4
2
2
1
1
7
4
1
2
1
1
1
9-11
075.1
9.5
Service Manual
Envelope hopper 2/2
RH
27
26
25
24
23 22 21 20
19 18 17 16 15
8
9
14 13 12 11
10
LH
9-12
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Spring clip 6 - 8 mm
Damper
Inside frame RH
Hinge axle
Inside frame (upper unit) RH
Damper suspension axle
Inside frame (upper unit) LH
Inside frame LH
Foot assy.
Buffer
Envelope feed axle
Jogger roller
O-ring
Feed roller 42 mm
Set screw M4x6
Conductive bearing 10 mm
Washer 16 x 10.2 x 0.8 mm
Cyl. pin 2.5 x 12
Slip clutch CCW 8mm
Timing belt
Pulley 15T (assy.)
Washer 14x8.2x 0.8 mm
Support plate
Lower damper pin RH
Spring clip 11-15 mm
2052446P
2964140V
2989139L
2964114T
2989162K
2964120Z
2989163L
2989136H
2994108M
2994072Z
2989410T
2975952Z
2041876D
2732731U
2082802K
2042426B
2040143Y
2052483C
2052347L
2957127Q
2951316M
2930554K
2040141W
2052454X
2964185S
2964117W
2053868V
2052473S
rev. 1.0 - 12/2009
Remarks
4
2
1
1
1
1
1
1
4
2
1
2
2
1
1
2
3
2
1
1
1
1
2
1
1
1
7
4
9-13
075.1
9.6
9-14
Service Manual
Envelope separation
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Stop plate
Lever
Separation adjustment lever
Hinge joint
Flat spring
Frame plate
Flanged bush
Separation roller support
Separation roller axle
Spring clip 5-7mm
Lifting axle
Separation roller (assy)
2809096R
2809098T
2809099U
2809097S
2053871Y
2809101W
2825201S
2454302P
2809160H
2053865S
2809094P
2809095Q
2052466K
2809100V
2994358X
rev. 1.0 - 12/2009
Remarks
1
1
1
1
4
1
1
4
4
2
1
1
2
1
1
9-15
075.1
9.7
Service Manual
Lower envelope track 1/2
10 11 12 13
1
RH
9
14 15 16 17 18 19 20 21 22
44
(10)
45
46
47
48
49
25 24 23
43 42 41 40 39
LH
55 54 53 52 51 50
38 37 36 35 34 33 32 31 30
9-16
29 28 27 26
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
Inside frame LH
Envelope guide plate LH
Upper frame envy. track
Cyl. pin 2.5 x 16
Sensor (including holder)
Bracket
Nut M4
Pan head tapping screw
Brush lifter
Tension spring
Clutch shaft
Transportation axle
Freewheel transportation axle
Transportation axle
Envelope guide plate RH
Fixing plate envelope track
Inside frame RH
Lifting bracket
Tension spring
Nut M4 (self-locking)
Draw bar
Clamping ring 3 mm
Spacer
Lever
Lifting frame
Mounting plate
Lifting roller
Sleeve
Pressure spring 0.85 mm
Air hose
Air tube plug
Air hose connector
Bracket
Hinge axle
Lower frame env. track
Led (including holder)
2825315L
2964259U
2053880H
2052483C
2040143Y
2042426B
2994303Q
2052346K
2995420D
2042453E
2964148D
2451902P
2453855Y
2043020V
2031175G
2964172D
2964175G
2964188V
2964171C
2964260V
2957304Z
2825316M
2053868V
2053872Z
2043022X
2033559Q
2053621N
2964128H
2052463G
2041098T
2964132M
2964124D
2453702P
2964125E
2964126F
2053871Y
2454318F
2041216R
2431112H
2031111Q
2241308V
2052455Y
2241302P
2041323C
2433429W
2453853W
2964322K
2964123C
2042452D
2951312H
2052454X
rev. 1.0 - 12/2009
Remarks
1
1
7
6
6
8
1
14
6
2
1
2
2
1
1
1
1
1
1
1
1
1
4
1
1
1
2
1
4
1
1
1
1
1
1
1
1
1
2
4
1
1
2
2
1
1
1
1
1
8
7
9-17
075.1
Service Manual
Number
Description
52
53
54
55

Axle
Axle for pressure rollers
2040141W
2042425A
2964153J
2964152H
9-18
Remarks
6
6
1
2
rev. 1.0 - 12/2009
Service Manual
075.1
Intentionally blank
rev. 1.0 - 12/2009
9-19
LH
9 10
9-20
30 29
26
27
28
31
32
25 24 23
35 36
22 21 20 19
13
12
11
18
17
16
15
14
9.8
33
34
RH
075.1
Service Manual
Lower envelope track 2/2
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Sleeve
Pin
Rubber roller
Transportation axle
Cyl. pin 2.5 x 16
Countersunk tapping screw
Bracket
Mounting plate
Hinge axle
Lifting plate
Clamping ring 3 mm
Connecting rod
Hinge pin
Axle for pressure rollers
Pressure spring
Pressure roller (assy.)
Flap scraper
Nut M4
Bracket
Flap opener
Draw bar
2964370K
2964371L
2042426B
2040143Y
2964190X
2052455Y
2052483C
2964171C
2052346K
2041827C
2053868V
2053866T
2053880H
2053856H
2964555C
2042453E
2964553A
2964554B
2431112H
2052442K
2964129J
2052463G
2964130K
2964131L
2964170B
2453702P
2033551G
2964556D
2453853W
2964145A
2451902P
2430535G
2964148D
2042452D
2964144Z
2964128H
rev. 1.0 - 12/2009
Remarks
2
1
6
5
1
2
3
1
4
4
12
4
5
1
1
1
1
1
2
2
2
4
2
2
1
4
4
4
1
1
1
1
1
1
1
1
9-21
LH
9-22
57
58
52 51
59 60 61
9 10 11 12 13
50 49 48
47 46 45 44
62 63 64 65
14 15 16 17 18 19 20
36
35
34
43 42 41 40 39 38 37
33
32
RH
21 22 66 23 24 25 26 27 28 29 30 31
9.9
56 55 54 53
075.1
Service Manual
Insert table and upper envelope track
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
Microswitch (incl. lever)

Spacer 15 x 10.4 x 3 mm
Cover
Frame axle
Protecting plate
Lock washer 5/32
Countersunk head screw M4 x 10
Upper sealing roller 36 mm
Mounting plate
Lower sealing roller (assy.)
Pressure spring
Tension pin 2 x 12
Actuator disc
Nut M4
Clamping ring 3 mm
Draw bar
Tension spring
Mounting bracket
Solenoid
Lever for finger
Pressure spring
Finger
Cross connection (incl. cork rubbers)
Cork rubber
Leaf spring
Finger slide
Pressure spring
Hex. head screw M4 x 8 (synthetic)
Knurled nut
Adjustable finger
Pulley axle (assy.)
Connecting ring
Transportation axle (assy.)
Transportation table (assy.)
Transportation roller
Cyl. pin 2.5 x 16
Pulse disc axle (assy.)
2989056Z
2453739C
2454305S
2040858T
2957152R
2957153S
2453853W
2957313J
2042453E
2042452D
2052431Y
2053868V
2453875U
2732648H
2957204V
2989433S
2031191Y
2040143Y
2042426B
2031111Q
2031115U
2454312Z
2042424Z
2053315U
2454316D
2964061N
2451902P
2052463G
2053621N
2964062P
2033504H
2964063Q
2021021E
2964065S
2964070X
2964071Y
2964568R
2041804D
2964564M
2964066T
2964073A
2964566P
2021125N
2964057J
2964358X
2964560H
2964357W
2964567Q
2964161S
2052346K
2041827C
2043007G
2964359Y
rev. 1.0 - 12/2009
Remarks
1
2
2
1
1
2
2
1
1
1
6
10
2
1
1
1
2
6
7
2
1
6
2
1
1
1
7
4
1
1
1
1
1
4
2
2
1
4
1
2
2
2
2
2
1
1
1
1
2
4
4
2
1
9-23
075.1
Service Manual
Number
Description
53
54
55
56
57
58
59
60
61
62
63
64
65
66
Hex. head screw M4 x 8

Sleeve
Pin
Pressure spring 1 mm
Wiring plate
Axle
Guide plate
Insert table
Countersunk head screw M3 x 8
Axle for fingers
Guide plate bracket
2053880H
2040140V
2964370K
2964371L
2031114T
2989158F
2454302P
2964169A
2825203U
2994300M
2050414X
2964059L
2052446P
2825218K
9-24
Remarks
8
1
2
1
10
1
2
1
1
1
6
1
3
2
rev. 1.0 - 12/2009
Service Manual
075.1
Intentionally blank
rev. 1.0 - 12/2009
9-25
LH
7
8
9-26
40 41 42 (34)
28 27 26 25 24
43 44 45 46 47 48 49
10 11 12 13 14 15 16
23 22 21 20 19 18 17
RH
9.10
39 38 37 36 35 34 33 32 31 30 29
075.1
Service Manual
Insert and eject mechanism
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49

Loc frame
Connecting plate loc
Rubber damping ring
Pressure spring
Solenoid
Bracket for photocell
Cross connecting plate
Timing belt
Pulley 21T
Cyl. pin 2.5 x 16
Drive axle
Washer 12 x 4.3 x 1 mm
Paper guide
Tension spring
Bearing plate
Spacer 15 x 10.4 x 7.5 mm
Gear 15T
Gear 14T
Axle
Gear 20T
Bearing plate
Bearing plate
Gear 15T
Rod
Transportation axle
Bearing plate
Clamping ring 3 mm
Draw bar
2825322T
2994383Y
2053880H
2053871Y
2957260D
2040027C
2031195C
2040141W
2121287Y
2453745J
2454311Y
2964731L
2453855Y
2042452D
2964729J
2825331C
2052442K
2041537A
2041870X
2052346K
2040143Y
2042426B
2964723C
2053868V
2453743G
2964730K
2964364D
2431112H
2052483C
2033562T
2964720Z
2040837W
2040828M
2240944R
2964179L
2964717W
2240258B
2964719Y
2041094P
2964721A
2040830P
2732942P
2432681S
2964718X
2964722B
2052463G
2432679Q
2040858T
2041827C
rev. 1.0 - 12/2009
Remarks
1
2
11
4
2
1
1
2
1
3
6
1
1
1
1
1
1
1
1
6
9
10
1
4
2
2
2
3
4
2
1
3
2
2
1
1
1
1
2
1
2
1
1
1
1
4
1
3
2
9-27
075.1
9.11
9-28
Service Manual
Moistening unit
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Bracket
Bearing 10mm
Pressure spring 0.85mm
Axle
Cyl. pin 2,5x16
Spring clip 10-14mm
Spring lever
Tension spring
Washer 12x4,3x1mm
Nut m4
Buffer assy.
Lock brush holder
Brush holder
Spring
Not used
Grommet
Brush
Retaining spring
Round head screw m4x6mm
Mounting bracket
Solenoid
Cross bar
2964734P
2042426B
2431112H
2825266K
2052346K
2052483C
2232874K
2456404D
2453743G
2053871Y
2451902P
2053621N
2833497J
2045517W
2042994T
2041893W
1
2
2
1
2
1
1
1
2
1
1
1
1
1
1
1
2120474B
2720005N
2031187U
2454312Z
2053868V
2053880H
2453868M
2053875C
2969319Q
2121287Y
2042977A
2964727G
3
3
3
2
2
12
1
2
1
1
2
1
rev. 1.0 - 12/2009
Remarks
9-29
9-30
LH
25 24 23
26 27 28
40
29 30 31 32 33 34 35 36 37 38 39
41
22
21
20
14
13
12
11
10
RH
15 16 17 18 19
9.12
42
43
44
075.1
Service Manual
Envelope closing mechanism
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44

Bracket photocells divert
Sensor (incl. holder)
Solenoid
Mounting frame
Lever
Brake plate assy.
Transportation roller (assy.)
Hinge bracket
Cyl. pin 12 x 16
Gear 15T
Pulley axle
Pulley/gear 15T
Timing belt
Protective plate loc
Loc frame
Cross bar
Grommet
Transportation axle
Bracket photocell - exit
Led (incl. holder)
Refer to 15
Ejection axle
Nut M4
Clamping ring 3 mm
Draw bar
Pressure spring
2454311Y
2994265A
2042453E
2121287Y
2809025R
2453745J
2964703G
2040140V
2994309W
2841704H
2052446P
2964702F
2053880H
2989162K
2052346K
2045413N
2043353S
2043352R
2041537A
2453868M
2994073A
2994383X
2964727G
2989163L
2989275C
2040858T
2040830P
2453855Y
2232600Z
2825339L
2042452D
2042426B
2031111Q
2052483C
2042977A
3
1
1
1
1
4
1
8
1
2
4
1
15
1
5
1
1
1
1
2
1
2
1
1
1
1
4
1
1
1
1
4
2
4
2
2041827C
2964724D
2040143Y
2451902P
2052463G
2809028U
2031195C
2040141W
2
1
3
2
4
1
1
2
Washer
rev. 1.0 - 12/2009
14 x 8.2 x 0.8 mm
Remarks
9-31
075.1
Main drive mechanism
RH
27 26 25 24 23 22 21 20 19 18
8 9
10
17 16 15
14
11 12 13
9.13
Service Manual
9-32
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Mounting bracket for spring

Fixing plate
Axle for tensioner roller
Cyl. pin 2.5 x 16
Tensioner roller
Pulley 20T assy. (timing belt)
Timing belt
Cyl. pin 2.5 x 20
Drive belt PJ
Main pulley
Tensioner roller
Pulley 50 Hz
Pulley 60 Hz
Set screw M4x8
Belt tensioner
Gear 30T
Gear 24T
Timing belt
Motor 220-240V/50Hz
Motor 100-115V/50-60Hz
Tensioner roller
2989116M
2053880H
2951307C
2040141W
2951310F
2052346K
2964368H
2042246P
2041621N
2052442K
2964193A
2964155L
2964369J
2964167Y
2989404M
2989405N
2082806P
2964166X
2052455Y
2040143Y
2964674B
2040828M
2453882B
2430851L
2930525E
2951316M
2989406P
2989407Q
2951319Q
rev. 1.0 - 12/2009
Remarks
3
8
2
2
2
5
1
4
1
2
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
1
1
1
9-33
075.1
Feeder/Folder driving mechanism
RH
21 20 19 18 17 16 15 14 13 12 11 10
9.14
Service Manual
9-34
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Cyl. pin 2.5 x 20

Disc for pulley
Pulley 28T
Timing belt
Tensioner roller
Pulley 36T
Clutch CW 8 mm
Gear 24T
Blocking bracket
Gear 20T
Blocking bracket
Belt tensioner
Hex. head screw m4x12
Washer 12x4,3x1mm
2964193A
2964356V
2825516V
2052454X
2964662P
2052483C
2964194B
2040141W
2964656H
2052446P
2040825J
2121666T
2930525E
2053880H
2235615Q
2964199G
2053868V
2964198F
2825337J
2453882B
2453743G
rev. 1.0 - 12/2009
Remarks
2
2
2
1
1
2
1
1
1
1
1
2
1
3
1
1
1
1
1
2
2
9-35
075.1
22
21
20
19
17
18
16
15
23
25 24
9 10 11 12
RH
32 31 30 29 28 27 26
14
Envelope track driving mechanism 1/2

13
9.15
Service Manual
9-36
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Belt tensioner
Tension pin 2.5 x 16
Gear 28T
Gear 18T
Cyl. pin 2.5 x 20
Disc for pulley
Timing belt
Pulley 36T
Mounting plate
Adj. plate
Pulse disc sensor (assy.)
Pulse disc
Clamping disc
Pulley 30T
Tensioner roller
Pulley 20T
Gear 35T
Gear 18T
Accessory connector (incl. wiring)
Locking plate
2964676D
2053880H
2053322B
2040837W
2240261E
2240936H
2052455Y
2040143Y
2964193A
2964356V
2964355U
2964160R
2052483C
2964180M
2053866T
2053865S
2453739C
2964181N
2821622P
2241281S
2433046X
2430790X
2454212V
2964164V
2964194B
2964157N
2246952Z
2040830P
2964351Q
2825940M
2053868V
2964165W
1
2
4
4
2
2
3
4
4
3
1
1
4
1
1
3
3
1
1
1
1
1
1
2
2
1
1
1
2
1
2
2
Remarks
See note
Note
In case the optional High Capacity Vertical Stacker (HCVS-1) is part of the system.
rev. 1.0 - 12/2009
9-37
RH
9-38
30 29 28
36 35 34 33 (23)32 31
27 26 25 24
37 38 39 40
19 18 17 16 15
9 10 11 12 13 14
9.16
23 (8) 22 21 20
(19)
075.1
Service Manual
Envelope track driving mechanism 2/2
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Cyl. pin 2.5 x 12

Slip clutch CCW 8mm
Timing belt
Pulley 15T (assy.)
Gear 35T
Catch disc
Clutch CW 8 mm
Cyl. pin 2.5 x 16
Gear 18T
Support plate
Gear 28T
Gear 35T
Freewheel clutch assy.
Gear 28T
Gear 14T
Nut
Spring holder disc
Gear 18T
Gear 15T
Gear 21T
Gear 15T (assy.)
Brake rod
Cyl. pin 12 x 16
Pulley 13T
Intermediate axle
2052347L
2957127Q
2951316M
2930554K
2042426B
2454213W
2041094P
2246958F
2235506B
2121666T
2052346K
2964174F
2040141W
2052446P
2053868V
2964185S
2052483C
2241140V
2246952Z
2964360Z
2052455Y
2240261E
2964179L
2451920H
2453738B
2246943Q
2031173E
2052454X
2240936H
2045413N
2241650B
2746942X
2040858T
2964184R
2040837W
2040964D
2053322B
2964177J
2964176H
2053324D
rev. 1.0 - 12/2009
Remarks
1
1
1
1
9
2
1
2
1
1
3
1
3
1
1
1
5
1
2
1
2
1
2
2
2
2
1
2
1
1
1
1
2
1
1
1
1
1
1
2
9-39
9-40
45 44 43 42 41 40
52
53
29
30
31
32
33
34
35
19
54
55
16
15
14
13
18
39 38 37
9 10 11 12
28 27 26 25 24 61 23 22 21 20
14
17
36
56
57
14
9.17
46 47 48 49 50 51
60 59 58
075.1
Service Manual
Document feeder unit (automatic)
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53

Pulley
Not used
Transportation axle
Not used
Transportation axle (separation)
Pressure spring
Bearing bush
Rubber paper puller
Paper puller axle assy.
Mounting strip
Upper plate feeder
Bottom plate assy. (daily mail feeder)
Frame plate feeder
Pressure spring
Spacer
Drive axle
Separation axle assy. (daily mail)
Cyl. pin 2.5 x 16
Fixing strip
Fixing strip
Sleeve
Slide
Nut M4
Wire spring
Drive axle extension
Hinge arm
Curved spring assy.
Spring lever
Cyl. pin 2 x 16
Gear 48T
Pulley 44T
Tensioner roller
Belt tensioner
Gear 64T (assy.)
Support axle extension
Fibre washer 10 x 5.2 x 1 mm
Bearing bush
2951167G
2053320Z
2951142F
2052442K
1
1
1
8
2042851U
2042853W
2
1
2951139C
2031114T
2040141W
2989311Q
2040016R
2042740D
2989321A
2989304H
2989326F
2989305J
2033520Z
2454319G
2053621N
2951337J
2053868V
2042425A
2964216Z
2042311G
2052346K
2951312H
2951182X
2989318X
2041157E
2951178T
2453743G
2451902P
2951179U
2454300M
2964220D
2989312R
2042880Z
2989309N
2052369J
2951132V
2951151Q
2951159Y
2989322B
2951170K
2951109W
2053319Y
2040107L
2041332M
2052466K
2042452D
2989310P
1
1
10
1
2
1
1
1
1
2
2
1
1
1
17
2
1
1
2
2
1
1
1
1
6
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1
rev. 1.0 - 12/2009
Remarks
Incl. item 13
9-41
075.1
Service Manual
Number
Description
54
55
56
57
58
59
60
61

Cork strip
DFC
Bottom plate assy.
Separation axle assy. (auto)
Blocking bracket
2453855Y
2951126P
2042453E
2790171C
2989308M
2951168H
2042263G
2989557W
9-42
Remarks
2
2
1
1
1
1
1
1
rev. 1.0 - 12/2009
Service Manual
075.1
Intentionally blank
rev. 1.0 - 12/2009
9-43
075.1
9.18
9-44
Service Manual
Document feeder unit - special 1/2
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
Torsion spring
Transportation roller special
Pulley
Hub
Tension roller arm
Spring clip 8-11mm
Tensioner roller
Gear 48t
Drive axle
Cyl. pin
Bearing 8mm
Separation axle extension
Transportation axle
Pressure spring
Bearing bush
Coupling sleeve
Spacer 12x8,3x3mm
Spring clip 5-7mm
Fibre washer 10x5,2x1mm
Support axle extension
Cyl. pin 2,5x16
Pan head screw M4x10 (Torx)
Gear 54T/16T
Gear 16t
Suspension bracket
Bearing 6mm
Pulley 20t
Spring clip 6-8mm
Spring clip 7-9mm
Washer 12x6,2x0,8mm
Washer 14x8,2x0,8mm
Rubber paper puller
Tension pin 2,5x12
Gear 64t assy.
Spring clip 4-5mm
Cyl. pin 2,5x10mm
Separation axle assy. (special)
Transportation roller assy.
2951250T
2043205N
2951251U
2951252V
2042740D
2989322B
2052454X
2045502F
2045348V
2951132V
2964224H
2052369J
2042425A
2951109W
2042853W
2042851U
2033520Z
2041332M
2951212D
2041050T
2052466K
2040107L
2053871Y
2951220M
2052346K
2045491U
2741288H
2964227L
2951232Z
2042424Z
2951142F
2052446P
2052442K
2040140V
2040141W
2040016R
2053320Z
2951170K
2052447Q
2052370K
2951312H
2042312H
2043203L
rev. 1.0 - 12/2009
1
1
1
1
1
1
2
1
1
1
1
2
2
1
1
2
2
2
2
1
2
3
2
1
2
2
2
2
2
2
1
2
6
2
8
2
4
1
2
2
2
1
1
Remarks
Incl. item 36
9-45
075.1
9.19
9-46
Service Manual
Document feeder unit - special 2/2
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Nylon bearing
Pan head tapping screw 2.9x6.5
Frame plate feeder LH
Support bracket (lower)
Bottom plate feeder
Mounting strip
Spacer
Paint piercing washer 8x4,3x0,5
Stop plate
Leaf spring
Clamping plate
Countersunk head screw M4x10 (Torx)
Nut m4
Torx screw m4x8
Support bracket (upper)
Frame plate feeder RH
Pan head screw M4x10 (Torx)
DFC
Upper plate feeder
Mounting plate
2040966F
2453865J
2053855G
2045482K
2951231Y
2989310P
2045487Q
2989321A
2454300M
2951337J
2052431Y
2045490T
2951207Y
2053871Y
2951246P
2045504H
2454318F
2053621N
2451902P
2053850B
2951214F
2454302P
2045481J
2045491U
2042453E
2790171C
2042452D
2045484M
2951234B
rev. 1.0 - 12/2009
Remarks
2
1
2
1
1
1
1
1
2
1
1
1
1
2
1
3
1
1
1
12
1
1
1
5
1
1
1
1
1
9-47
075.1
9.20
Service Manual
Document feeder trays
1
2
3
RH
22
21
20
4
5
6
LH
7
8
19
18
17
16
15
9
10
11
12
13
14
9-48
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Guide roller (assy.)
Side guide RH
Side guide LH
Gear
Pressure spring
Carrier
Carrier
Washer 15 5.3 x 2 mm
Finger knob
Nut M4
Knurled nut
Self-locking nut
Short feeder tray - 1 piece
Short feeder tray - set of 2 pieces
Short feeder tray - 1 piece - special
Locking lever
Roller
Adj. rod
Lever
Hinge
Hinged side guide
2451240Z
2042709W
2825470X
2825471Y
2951014X
2430247G
2033520Z
2041132D
2042737A
2042738B
2453750P
2741497A
2451902P
2042749N
2053621N
2042651L
2042727Q
2100980V
2100956V
2951019C
2951022F
2951020D
2951025J
2825472Z
2454211U
1
2
1
1
2
1
2
Document feeder tray complete

Document feeder tray complete
2825341N
2825340M
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
-
Remarks
Optional
See note
See note
See note
See note
Optional
Optional
Optional
See note
Automatic
Special
Note
These parts are part of the special feeder.
rev. 1.0 - 12/2009
9-49
075.1
9.21
9-50
Service Manual
Vertical track (base)
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
Frame axle
Drive axle
Drive axle assy.
Bearing 10mm
Center cover plate
Guide plate
Cover plate
Blocking bracket
Countersunk tapping screw
Adjustment plate
Hinge pin
Frame axle
Lower cover plate
Microswitch (including lever)
Mounting plate
Nut M3
Tension spring
Disc
Mounting bracket for spring
Tension spring
Lever
Tension pin 2,5x12
Tension spring
Washer 16x10,2x0,8mm
Nylon bearing
Spring clip 9-12mm
Washer 7x3,2x0,5mm
Timing belt
Pulley 44t
Clutch ccw 8mm
Cyl. pin 2,5x16
Bearing 8mm
Spring clip 6-8mm
Spacer 12x8,4x5mm
Lock axle
Transport roller 30x10x11
Feeder frame assy. LH
Feeder frame assy. RH
Mounting plate
2951303Y
2964653E
2951314K
2042426B
2964625A
2825383G
2951327Y
2964677E
2453856Z
2054313J
2825325W
2989323C
2053880H
2951324V
2964615Q
2053866T
2989056Z
2989187L
2053868V
2451901N
2455404M
2930539U
2989116M
2951150P
2951021E
2053320Z
2951328Z
2040143Y
2041271Y
2052455Y
2453739C
2041574P
2951308D
2930536R
2052346K
2042425A
2052446P
2040964D
2825324V
2053867U
2995420D
2825394T
2042452D
2825395U
2965331L
2995419C
rev. 1.0 - 12/2009
Remarks
1
1
2
1
1
1
2
3
1
2
2
6
15
3
1
11
1
1
11
2
3
3
3
3
3
3
3
3
6
6
5
3
3
3
6
2
3
6
1
3
2
1
1
1
1
4
9-51
075.1
9.22
9-52
Service Manual
Vertical track (loc)
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
Frame vertical transport

Guide plate
2825388M
2825391Q
1
1
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Mounting bracket
Guide plate (lower)
Positioning plate
Nut m4
Pressure roller axle
Tension spring
Locking plate
Guide axle
Paper guide
Hinge pin
Pressure spring
Bearing 6mm
Washer 12x6,2x0,8mm
Spring clip 6-8mm
Guide plate (upper)
Locking bracket
Locking bracket
Reading head assy.
2964143Y
2825384H
2989157E
2451902P
2453853W
2453868M
2042852V
2033561S
2825263G
2964201J
2995002T
2964112R
2453871Q
2033520Z
2042851U
2042424Z
2040140V
2052446P
2053880H
2825382F
2825427C
2825431G
2042453E
2989434T
1
1
1
1
1
12
3
2
1
2
4
2
2
6
6
6
6
6
2
1
1
1
1
1
24
25
rev. 1.0 - 12/2009
Remarks
without
reading
option
installed
Francotyp
9-53
9-54
LH
41 40 39 38 37 36 35 34 33 32 31
42 43
46
48
49
44
8
9
30 29 28 27
50 51 52 53 54 55
26 25 24 23 22 21 20
19 18 17 16 15 14 13 12 11
10
RH
9.23
47
45
075.1
Service Manual
Collating unit (upper)
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
Inside frame LH
Tension spring
Nut M4
Hinged guide plate
Leaf spring
Frame
Inside frame RH
Roller
Cyl. pin 2 x 16
Frame (collator area)
Axle
Tensioner
Pressure spring
Guide plate
Pressure roller assy. (incl. O-ring)
Hinge axle
Pressure spring
Axle
Belt tensioner
Set screw M4x4
Nylon bearing
Collating belt set (3 pcs.)
Drive axle (collator area)
Set screw M4x4
Roller
Bushing 15 x 10.2 x 5.5 mm
Frame collator motor
Motor 24V
Set screw M3x4
Pulse disc
Spring clip 8 - 11
Clamping ring
Mounting bracket
Pressure roller 20 mm
Axle 6 mm
2825315L
2033539U
2451902P
2964134P
2042453E
2453855Y
2989423G
2964304R
2053880H
2825316M
2989401J
2052369J
2040140V
2042424Z
2964302P
2964306T
2964300M
2964332V
2964301N
2052446P
2952011L
2964308V
2033543Y
2964309W
2952015Q
2082801J
2041107C
2052447Q
2053865S
2952007G
2989422F
2042425A
2040143Y
2082801J
2989400H
2753751Q
2989421E
2989409S
2975505J
2082833S
2964343G
2053866T
2053871Y
2052454X
2052486F
2053868V
2453853W
2964312Z
2042452D
2951408H
2989424H
rev. 1.0 - 12/2009
Remarks
1
2
1
1
2
2
1
1
7
1
6
6
10
2
1
1
1
2
1
6
3
4
2
1
2
2
4
8
3
1
1
1
3
1
3
1
1
1
1
5
1
2
4
1
1
3
2
1
2
2
1
9-55
075.1
Service Manual
Number
Description
52
53
54
55
Cyl. pin 2.5 x 16

Transportation axle (assy.)
Paper guide strip
2052346K
2041827C
2964655G
2964133N
9-56
Remarks
2
2
1
1
rev. 1.0 - 12/2009
Service Manual
075.1
Intentionally blank
rev. 1.0 - 12/2009
9-57
075.1
9.24
Service Manual
Collating unit (lower) and power supply
1
2
3
5
6
45 46 47 48 49 50 51
7
8
9
10
11
12
13
14
44
43
42
41
40
39
38
37
36
35
34
15
16
17
33
32
31
30
RH
18
19
20
21
LH
29
28
9-58
27
26
25 24 23 22
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
Collating plate
Collator stop axle
Paper stop
Locking plate rack
Gear rack
Pulse disc sensor
Screw M4x8
Bracket (for pulse disc sensor)
Cover plate RH
Screw M2x4
Gear
Bottom frame collator assy.
Spring
Microswitch (incl. lever)
Screening plate
Isolating plate
Printed board holder
Motor relay board 230V
Guide plate
Tension spring
Hinge axle
Fuse 2.5A/230V slow blow
Fuse 5A/125V
Power inlet
Foot assy.
Power supply
Power supply frame
Capacitor 5 mF (230 V)
Lock washer 5/32
Motor collator stop 24v
Guide roller
Grommet
Cover plate LH
Hinge axle
Clamping ring 4 mm
Rod
Counter roller
Nut M4
Axle
2994209S
2053868V
2994230P
2952141W
2994241A
2994231Q
2975505J
2053868V
2994234T
2964328R
2994237W
2994238X
2994229N
2994236V
2989056Z
2964337A
2454305S
2453875U
2989004V
2041075U
2975500D
2975540V
2989201A
2052446P
2033536R
2989204D
2975543Y
2121549W
2989005W
2994108M
2053880H
2989002T
2989203C
2989006X
2121281S
2989006X
2121281S
2453702P
2052431Y
2994232R
2964319G
2120983G
2964327Q
2964322K
2052483C
2052462F
2964325N
2952111Q
2451902P
2453745J
2952112R
rev. 1.0 - 12/2009
Remarks
1
16
2
2
1
1
2
1
1
1
2
1
1
2
1
1
2
1
1
4
1
1
2
6
2
1
1
1
1
2
2
1
1
1
1
1
1
2
2
1
2
1
1
1
4
2
1
18
4
4
2
9-59
075.1
Service Manual
Number
Description
48
49
50
51
Tilting plate
Tension spring
Roller
Transportation axle
2952114T
2456404D
2952113S
2964324M
9-60
Remarks
2
1
1
6
rev. 1.0 - 12/2009
Service Manual
075.1
Intentionally blank
rev. 1.0 - 12/2009
9-61
9-62
LH
(18) (21)(18)
26
22 21 20 19 18 17 16 15 14
23 24 25
(10)
27
28
29
30
31
13 12 11 10
RH
9.25
32
33
075.1
Service Manual
Folder unit (base)
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Bearing locking plate

Upper input roller (assy.)
Lower input roller (assy.)
Screening plate (assy.)
Wiring guide
Cyl. pin 2.5 x 16
Gear 24T
Gear 35T
Flap actuator
Cyl. pin 2 x 12
Sleeve
Fixing screw M3x6
Flap assy. incl. torsion spring
Torsion spring
Flap assy. (incl. axle)
Synthetic leaf spring
Guide bracket
Guide strip
2930613W
2453750P
2053875C
2042424Z
2040140V
2052446P
2053880H
2430790X
2930612V
2825300V
2825313J
2964264Z
2964258T
2053865S
2053874B
2454300M
2052346K
2930525E
2052483C
2040858T
2246958F
2040143Y
2953084D
2953085E
2053871Y
2040027C
2953083C
2042771L
2033538T
2042750P
2930654P
2953073S
2930653N
rev. 1.0 - 12/2009
Remarks
2
4
6
4
4
4
5
2
2
3
1
1
1
4
2
2
3
3
5
4
2
2
2
2
2
2
4
2
2
2
4
1
1
9-63
075.1
9.26
Service Manual
Folder unit (loc) 1/4

1
9 10 11
RH
12 13 14 15
21 20
19
LH
18
17
16
22 23 24
RH
25 26 27 28 29 30 31
LH
33
32
9-64
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33

Leaf spring
Locking plate
Bracket
Curve axle
Mounting bracket
Curve disc RH
Guide plate (assy.) (first fold table)
Axle for fold plate
Hinge plate RH
Fold plate
Hinge strip (paper guide) LH
Hinge plate LH
Curve disc LH
Nut M4
Mounting bracket
Guide plate (second fold table)
Paper guide
Pressure spring
Stop nut
Set screw M4x4
Hinge strip (paper guide) RH
Bushing
Fold plate
Hinge strip (paper guide) LH
2053871Y
2953060D
2053868V
2953095Q
2953090K
2052483C
2042426B
2053324D
2953110F
2953056Z
2043362B
2953051U
2053874B
2953030X
2953011C
2964207Q
2953020M
2953010B
2040141W
2052442K
2043361A
2451902P
2453743G
2953059C
2953053W
2953026T
2031195C
2975335G
2082801J
2975273S
2975345S
2953016H
2975272R
rev. 1.0 - 12/2009
Remarks
4
2
2
1
2
4
4
4
2
1
2
1
14
2
2
1
2
2
4
4
2
2
2
1
1
1
2
2
3
1
2
1
1
9-65
075.1
LH
10
RH
9.27
Service Manual
9-66
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
Gear 32T (incl. catch)
Clutch CCW 8 mm
Cyl. pin 2.5 x 12
Clutch CW (clockwise) 8 mm
Drive axle (fold)
2042425A
2041050T
2040141W
2052442K
2964219C
2121461E
2052347L
2040871G
2121463G
2930510P
rev. 1.0 - 12/2009
Remarks
2
1
6
4
2
1
2
2
1
1
9-67
075.1
25 24 23 22 21 20 19
26 27 28
18 17 16 15
LH
14 13 12 11 10
9.28
Service Manual
9-68
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Lever for flap actuator

Cyl. pin 2 x 32
Bracket
Pulse disc sensor
Guide plate
Upper fold roller (assy.)
Fold roller (assy.)
Guide strip
Torsion spring
Ball bearing
Positioning lever
Brake disc
Cyl. pin 2.5 x 16
2953031Y
2052308V
2052454X
2040141W
2042425A
2989163L
2975461N
2975505J
2454311Y
2964138T
2053866T
2825307C
2825300V
2953073S
2453865J
2930613W
2453750P
2053875C
2953070P
2053871Y
2031281S
2953068M
2053621N
2040143Y
2052455Y
2953066K
2052346K
2042426B
rev. 1.0 - 12/2009
Remarks
2
2
2
4
2
1
2
2
8
1
1
1
1
1
1
1
2
2
2
2
2
2
2
6
2
2
2
2
9-69
36 35 34 33 32
31 30 29 28
9-70
21 20
13 14 15 37
12
11
10
19
18
17
16
9.29
27 26 25 24 23 22
RH
075.1
Service Manual
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37

Belt tensioner
Tension axle
Spacer
Brush lever
Locking plate
Cyl. pin 2.5 x 12
Slip clutch CCW 8mm
Pulley 18T
Tensioner roller
Timing belt
Pulley
Gear 24T
Cyl. pin 2.5 x 16
Gear 35T
Pressure spring
Brake disc
Brake strip
Guide strip
Fold roller (assy.)
Upper fold roller (assy.)
Guide plate
Spacer 12 x 8,3 x 7,5 mm
2989162K
2040141W
2042425A
2053875C
2052454X
2825334F
2053866T
2964669W
2041098T
2043021W
2053880H
2964165W
2052347L
2957127Q
2825332D
2430247G
2951319Q
2975255Y
2964160R
2052483C
2930525E
2052346K
2041094P
2246958F
2040858T
2453750P
2930613W
2953100V
2953094P
2953097S
2042426B
2053868V
2953073S
2825300V
2825307C
2964138T
2040859U
rev. 1.0 - 12/2009
Remarks
1
7
2
4
3
1
7
1
1
1
1
1
1
1
1
1
1
1
1
2
2
4
1
1
2
2
1
2
4
1
2
1
1
1
1
1
1
9-71
075.1
9
8
3
1 2
19 18 17
LH
16 15 14 13 12
11
Electrical components
10
9.30
Service Manual
9-72
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Color touch screen

Ejot screw 3x10
Display connector board
Grommet
Mounting bracket display
Spacer nut
Wiring display 075.1
Keyboard PCB
PCB holder
Communication board
Lock washer 5/32"
Main board 075.1
Pre-programmed main board 075.1
Spacer 8 x 4 x 25 mm
Dongle socket
Empty flex dongle
PCB holder
Pop rivet
ID tag
2994510F
2989182F
2994502X
2120480H
2994048Z
2454310X
2994074B
2989082B
2994508D
2041657A
2992000R
2454320H
2052431Y
2825900V
2825942P
2040883U
not applicable
2994506B
2930807Y
2994107L
2994504Z
15
16
17
18
19
rev. 1.0 - 12/2009
Remarks
1
4
1
1
1
2
4
1
1
2
1
1
1
1
1
1
5
1
1
9-73
075.1
9.31
9-74
Service Manual
High capacity feeder 1/4
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Pulley assy. 25T (timing belt)

Spacer
Spring clip 6-8mm
Washer 6,4 (B)
Spacer 12x8,4x5mm
Timing belt
Timing belt
Timing belt
Clutch ccw 8mm
Spring clip 8-11mm
Blocking bracket
Spring clip 7-9mm
Tensioner roller
Washer 14x8,2x0,8mm
Axle for tensioner roller
Fixing plate
Tensioner roller
Timing belt
Pulley 20T(timing belt)
Hex head screw M4x8
Washer
Cyl. pin 2,5x16
Pulley assy. 25T (RPM)
Hinge arm 1 assy.
Lever arm 2 assy.
Pulley assy. 25T
Hinge arm 2 assy.
Belt tensioner
2825033S
2040825J
2052446P
7175107
7180820
2040964D
2825051L
2825012V
2825096H
2930536R
2052454X
2453868M
2964677E
2052442K
2964368H
2040141W
2951310F
2951307C
2054313J
2964194B
2951316M
2241375Q
2453881A
2253757N
2052346K
2825031Q
2825026K
2825028M
2825021E
2825024H
2964166X
rev. 1.0 - 12/2009
Remarks
1
1
1
1
1
2
1
1
1
1
3
1
1
1
1
4
1
1
1
1
1
3
3
1
4
1
1
1
2
2
1
9-75
075.1
9.32
9-76
Service Manual
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
24
25
26
26
27
28
29
30
31
32
33
34
35
Spacer 10x5,3x10mm
Spring clip 8-11mm
Transportation plate
Tension spring
Cover plate HCF
Drive axle
Ball bearing
Transportation axle
Bearing 8mm
Cyl. pin 2,5x16
Locking plate
Ball bearing
Spring clip 10-14mm
Washer 12x6,2x0,8mm
Tension spring
Frame axle
Spring clip 5-7mm
Journal
Hex head screw M4x8
Nylon bearing
Bar
Washer 14x8,2x0,8mm
Spring clip 6-8mm
Axle HCF
Hinge axle
Lower arm HCF
Frame assy. LH
HCF lever
Frame assy. RH
U-frame
2040951Q
2052454X
2825035U
2825068D
2825061W
2951304Z
2031290B
2825001J
2042425A
2052346K
2825049J
2964675C
2052483C
2040140V
2031154K
2951303Y
2052466K
2825007Q
2453881A
2454318F
2040966F
2053621N
2825004M
2040141W
2052446P
2454211U
2825082T
2825040Z
2454312Z
2995419C
2825088Z
2825080R
2825091C
2825081S
2825084V
rev. 1.0 - 12/2009
Remarks
1
7
1
2
1
1
1
1
3
4
2
2
2
2
1
2
2
2
11
1
3
1
1
6
4
4
1
2
5
4
1
1
1
1
2
9-77
075.1
9.33
9-78
Service Manual
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
Remarks
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Paper pulley axle assy.

Tension pin 2,5x12
Cyl. pin
Gear 48t
Torx screw m4x8
Separation axle extension
Blocking bracket
Spring lever
Gear 20T
Transportation axle (separation)
Pressure spring d=1mm
Bearing bush
Rubber paper puller
Tension pin 2,5x10mm
Fibre washer 10x5,2x1mm
Spring clip 5-7mm
Separation roller (upper)
Pulley 20t
Bearing bush
Transportation axle
Spring clip 7-9mm
Hinge arm
Curved spring
Spacer 12x8,3x3mm
Bearing 8mm
Cyl. pin 2,5x10mm
Gear 16t
Drive axle
Washer 14x8,2x0,8mm
Cyl. pin 2,5x16
Transportation axle
Spring clip 6-8mm
Bearing 6mm
Pressure spring
Washer 12x6,2x0,8mm
Gear 64t assy.
Separation axle assy.
2042740D
2053320Z
2052369J
2825045E
2951132V
2053850B
2825029N
2989557W
2989309N
2975281A
2951139C
2031114T
2989311Q
2040016R
2053319Y
2040107L
2052466K
2951167G
2951142F
2041332M
2825006P
2052442K
2989312R
2951106T
2041050T
2042425A
2052370K
2964227L
2964224H
2040141W
2052346K
2825005N
2052446P
2042851U
2042424Z
2033520Z
2040140V
2951170K
2042263G
2995419C
Incl. item 14
rev. 1.0 - 12/2009
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
1
1
1
1
8
1
1
2
4
2
2
1
7
4
2
5
4
4
4
5
1
1
4
9-79
075.1
9.34
9-80
Service Manual
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Nylon bearing
Feeder plate assy. (rear)
Feeder plate assy. (lower)
Torx screw m4x8
Sleeve
Cover plate
Inside frame HCF LH
Mounting strip
Upper plate HCF
Mounting bracket
Cork strip
Nut m4
Slider
Wire spring
DFC
Inside frame HCF RH (assy.)
Fixing strip
2040966F
2453882B
2453855Y
2453865J
2825032R
2825057S
2053850B
2041157E
2825098K
2825008R
2825030P
2825010T
2825059U
2951126P
2451902P
2825063Y
2989313S
2790171C
2042453E
2042452D
2825074K
2989318X
2
1
2
2
1
1
17
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
HCF tray complete
2825526F
rev. 1.0 - 12/2009
Remarks
9-81
075.1
9.35
9-82
Service Manual
High capacity feeder tray
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Nut m4
Washer 15x5,3x2mm
Knurled nut
Base plate assy. LH (side guide)
Side guide HCF
Rotation plate
Gear 16T
Spring clip 5-7mm
Gear 70T
Guide bush
Guide axle
Top plate assy.
Adjusting plate
Base plate assy. RH (side guide)
2053621N
2451902P
2453750P
2042749N
2825042B
2825521A
2825504H
2454211U
2964566P
2825519Y
2052466K
2825520Z
2454212V
2053868V
2825506K
2825502F
2825512R
2825523C
2825522B
rev. 1.0 - 12/2009
Remarks
1
1
1
1
1
2
1
3
2
1
1
1
9
4
2
1
1
1
1
9-83
075.1
9.36
9-84
Service Manual
Side exit 1/3
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Scotch tape
Self-sticking plug
Bracket
Connecting frame
Guide spring
Washer 9 x 4,3 x 0,8mm
Knurled nut
Nut m4
Transparent cover
Bearing bush
Pulley
Washer 12x4,3x1mm
Tension pin 2,5x16mm
Spacer 8x4,3x7,5mm
Drive axle
Bearing
Socket head screw m5x10
Gear 15T
Gear 18t
Set screw M4x4
Spring clip 9-12mm
Nut m4 half d.
Bottom plate
Transportation table
Belt
2042451C
2959035C
2957389N
2453871Q
2957364M
2241008H
2453745J
2021125N
2451902P
2957393S
2957365N
2957374X
2453743G
2053322B
2040778K
2970101E
2042426B
2052850K
2240857A
2957376Z
2040143Y
2454213W
2082801J
2052455Y
2451919G
2957390P
2957366P
2957378B
rev. 1.0 - 12/2009
Remarks
1
2
1
2
1
1
9
1
11
1
1
2
1
1
2
1
2
2
1
1
2
1
2
1
2
1
1
2
9-85
075.1
9.37
9-86
Service Manual
Side exit 2/3
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
Part number Quantity Remarks
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Torsion spring
Spring clip 4-5mm
Washer 9x3,2x0,8mm
Spacer 3,2x5x12,5mm
Spacer 11x9.2x2.5 mm
Washer 12x6,2x0,8mm
Guide bracket
Conical roller
Spring clip 8-11mm
Washer 14x8,2x0,8mm
Spring clip 10-14mm
Mounting plate
Washer 12x4,3x1mm
Spacer 8x4,2x8,5mm
Pulley
Guide plate
Arm for conical roller
Bracket
Pulley assy.
2033535Q
2052447Q
2453746K
2957372V
2430125E
2040140V
2454306T
2957385J
2957368R
2052454X
2040143Y
2040141W
2052483C
2957391Q
2453743G
2957363L
2454316D
2957362K
2957394T
2957370T
2957361J
2957377A
rev. 1.0 - 12/2009
2
2
2
2
2
2
3
1
2
4
4
4
2
1
4
4
4
6
1
2
1
2
9-87
075.1
9.38
9-88
Service Manual
Side exit 3/3
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
Side guide
Cover
Envelope support
Bottom plate
Washer 12x4,3x1mm
Crinkle washer
Absorber
Upper plate assy.
2957381E
2053621N
2957386K
2957382F
2453871Q
2453745J
2957383G
2453743G
2052484D
2241151G
2453866K
2957387L
rev. 1.0 - 12/2009
Remarks
1
1
1
1
4
4
1
1
1
6
1
1
9-89
075.1
9-90
Service Manual
rev. 1.0 - 12/2009
Service Manual
10
Appendix
10.1
075.1
Recommended spare parts
Page ref.
Legend
no.
Description
Part No
Stock per
number of
installed
machines
1
10
Remarks
50
page 9-6
12
Moistening cloth
2040306T
page 9-8
11
Stop button assy.
2825452D
12
Start button assy.
2825451C
13
Feed roller
2732731U
21
Pulley 15T (assy).
2930554K
20
Timing belt
2951316M
19
Slip clutch CCW 8 mm
2957127Q
15
Conductive bearing 10
mm
2042426B
16
O-ring (for jogger

roller)
2041876D
page 9-14
15
Separation roller
(assy.)
2994358X
page 9-16
30 mm
2995420D
10
Sensor (including
holder)
2042453E
49
LED (including holder)
2042452D
50
30 mm
2951312H
16
53
mm
2042425A
16
Rubber roller
2964190X
28
Pressure roller (assy.)
2964556D
page 9-12
page 9-20
rev. 1.0 - 12/2009
42 mm
10-1
075.1
Page ref.
Service Manual
Legend
no.
Description
Part No
Stock per
number of
installed
machines
1
page 9-22
10
50
Upper sealing roller

36 mm
2732648H
Lower sealing roller

(assy.)
2989433S
mm
2042424Z
16
33
Solenoid
2021021E
36
Finger
2964071Y
38
Leaf spring
2964564M
41
Hex. head screw

M4 x 8 (synthetic)
2964566P
43
Adjustable finger
2964057J
47
Transportation table
(assy)
2964567Q
Solenoid
2121287Y
18
Timing belt
2041537A
27
30 mm
2964364D
42
Gear 15T
2732942P
28
38 mm
2042977A
20
Retaining spring
2031187U
18
Grommet
2120474B
19
10-2
2989056Z
23
page 9-30
Microswitch (including
lever)
16
page 9-28
1
14
page 9-26
Remarks
Brush
2720005N
12
10
(assy.)
2841704H
Remark: also
contains insert
rollers
2040945J
rev. 1.0 - 12/2009
Service Manual
Page ref.
Legend
no.
Description
Part No
075.1
Stock per
number of
installed
machines
1
page 9-32
10
Remarks
50
Timing belt
2041621N
12
Drive belt PJ
2964155L
11
Timing belt
2964355U
19
Pulse disc sensor

(assy.)
2821622P
20
Pulse disc
2241281S
25
Tensioner roller
2964194B
page 9-38
10
Clutch CW 8 mm
2121666T
page 9-40
Upper separation
roller*
2951167G
13
Rubber paper puller
2040016R
14
2042740D
57
DFC
2790171C
59
Separation roller
(lower)*
2951168H
43
assy.
2043203L
42
Separation axle assy.

(special)*
2042312H
37
(special)*
2043205N
Document feeder tray

automatic
2825341N
Document feeder tray

special
2825340M
Clutch CCW 8 mm
2930536R
page 9-36
page 9-44
page 9-48
page 9-50
34
rev. 1.0 - 12/2009
10-3
075.1
Page ref.
Service Manual
Legend
no.
Description
Part No
Stock per
number of
installed
machines
1
10
Remarks
50
page 9-52
25
Reading head assy.
2989434T
page 9-54
21
Pressure roller assy.

(incl. O-ring)
2952011L
30
Collating belt set (3

pcs.)
2952007G
38
Motor 24V
2989409S
50
Pressure roller 20
mm
2951408H
14
Spring
2994236V
21
2975500D
2975540V
27
Power inlet
2989005W
36
Motor collator stop 24V
2994232R
10
Upper input roller

(assy.)
2825300V
11
Lower input roller

(assy.)
2825313J
Clutch CCW 8 mm
2121461E
Clutch CW (clockwise)
8 mm
2121463G
Lever for flap actuator
2953031Y
12
Upper fold roller assy
2825307C
13
Fold roller assy
2825300V
17
Tensioner roller
2951319Q
page 9-58
page 9-62
page 9-66
page 9-68
page 9-70
10-4
Remark: O ring
2040274K not
separately
fittable
rev. 1.0 - 12/2009
Service Manual
Page ref.
Legend
no.
Description
Part No
075.1
Stock per
number of
installed
machines
1
page 9-72
10
Remarks
50
Color touch screen
2994510F
Display connector
board
2994502X
Keyboard PCB
2994508D
14
Main board 075.1
2825900V
Pre-programmed main
board
2825942P
11
Communication board
2992000R
Timing belt
2825051L
Timing belt
2825012V
Timing belt
2825096H
Side guide HCF
2825521A
no ref.
Socket modem
(optional)*
2992002T
no ref.
Serial cable INF

interface
2994542P
no ref.
Phone cable external
2992005W
no ref.
Connection board
expanded (optional)*
2992003U
page 9-74
page 9-82
rev. 1.0 - 12/2009
10-5
075.1
10.2
Service Manual
Electrical diagrams
Board number
Board name
Refer to
2994502X
Display board
page 10-7
2994508D
Keyboard
page 10-9
2975540V (115 V) or
2975500D (230 V)
Motor relay board
page 10-10
2992003U (regular) or
2992001S (expanded) (optional)
2992002T (optional)
Connection board
page 10-12
page 10-13
2992000R (optional)
Communication board
page 10-14
2825900V or
2825942P
Main board
Pre-programmed main board
page 10-19
-
2994504Z
ID Tag
page 10-31
10-6
Modem board
rev. 1.0 - 12/2009
OLOR
STN
SPLAY
CCFL_GND
+3.3V
LCD_D0
LCD_D1
LCD_D2
LCD_D3
LCD_D4
LCD_D5
LCD_D6
LCD_D7
GND
LCD_FRM
LCD_CLK1
LCD_CLK2
LCD_DOFF
GND
2130-2161
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
J104
GND
J100
2
4
6
8
10
12
14
16
18
20
R113
10K
R104
10K
R114
56K
VDD_P
GND
VDD_A
DIM_CLK
R129
R139
R132
R131
R133
R119
R118
R125
R124
R127
R126
R121
R122
R123
R128
GND
C133
100nF
2
5
7
10
12
15
1Q
2Q
3Q
4Q
5Q
6Q
GND
3
4
6
11
13
14
GND
+3.3V
R134
10K
R150
10K
U104D
74HC14_3
3.3
U102
74HC174
1D
2D
3D
4D
5D
6D
CLK
CLR
+3.3V
U104C
74HC14_3
3.3
6
Q
Q
CL
CLK
4
1
U103A
74HC74
R141
10K
+3.3V
3.3
LCD_DD0
LCD_DD1
LCD_DD2
LCD_DD3
SPI_TOUCH_CS
SPI_ADC_DATA_IN
GND
TP101
GND
C113
470pF
C102 *
1.3pF
GND
+3.3V
GND
C122
100nF
8
7
15
14
13
12
16
J101
R116
150R
GND
+3.3V
CO102
100nF
REF
GND
CS
DIN
BUSY
DOUT
DCLK
AUX
BAT
BACK LIGHT
CO103
100nF
GND
C107
100nF
C106
100nF
C105
100nF
GND
R109
10K
R137
10K
GND
Audio driver
C110
100F
2 BP
3 + V-
4 1 SD V+
C118
470pF
GND
GND
GND
CO105
100F
C119
470pF
CO101_3
470pF
VCC_OUT
GND
GND
D100
BAT54S
+3.3V
CO101_2
100nF
GND
3
C120
470pF
GND
GND
R135
10K
13
11
12
GND
YB
XL
YT
XR
2130-2041
1
2
3
4
J103
LS100
20CS08KQ
D103
BAT54S
+3.3V
U103B
74HC74
CL
CLK
470pF
C121
GND
D102
BAT54S
+3.3V
U104F
74HC14_3
12 3.3 13
GND
D101
BAT54S
+3.3V
GND
U105
LM4871
L1
L2
VCC_OUT
R105
10K
Touchscreen controller
CO101_1
100F
CO104
100nF
GND
U101
MXB7846
X+
Y-
X-
Y+
R138
150R
DAC_SOUND
JAE/ IL-G-4P-S3T2
1
2
3
4
R110
150R
IRQ
R117
150R
11
C114
470pF
R120
10K
CCFL_GND
C123
100nF
Backligth
current
readback
R115
150R
Q100B
SI4946EY
SGE2671-1 1:50
C112
470pF
[2] SPI_ADC_DATA_OUT
[2] SPI_CLK
[2]
DAC_CONTRAST
LCD_CL1
C111
470pF
R136
56K
D104
BAT54S
LCD_ENABLE
LCD_CL1
LCD_FRM
GND
LCD_CL2
CO100_3
100nF
C100
470pF
C104
100nF
CCFL_GND
C103
100F
R108
10K
Q100A
SI4946EY
R107
10R
3
U104B
74HC14_3
U104A
74HC14_3
2 3.3 1
SPI_ADC_DATA_IN
SPI_MPLEX_CS2 [2]
SPI_ADC_DATA_OUT [2]
DAC_CONTRAST
DAC_SOUND
LCD_CL1
LCD_CL2
LCD_DD0
LCD_DD1
LCD_DD2
LCD_DD3
LCD_FRM
LCD_ENABLE
SPI_MPLEX_CS1 [2]
SPI_CLK [2]
20
1
12
17
16
15
13
2
3
CCFL_GND
U100
LX1689
EA_IN
OC_SNS
OV_SNS
I_SNS
EA_OUT
DIM_MODE
DIV_248
BRITE_C
BRITE_IN
BRITE_R
BRITE_OUT
I_R
A_OUT
B_OUT
B/W to color data converter
10R
10R
10R
10R
150R
10R
10R
10R
10R
10R
10R
10R
10R
10R
10R
GND
CO100_1
100nF
V_batt
ENABLE
CO100_2
100nF
19
4
5
6
7
9
8
14
11
18
10
Mainboard connection
MicroMatch20`/SMD
1
3
5
7
9
11
13
15
17
19
+3.3V VCC_OUT
R111
10K
R112
10K
R103
10K
R106
10K
R100
10K
R101
10R
R102
10R
8
7
1
VCC_OUT
5
6
3
C101
100nF
10
VDD
1
VDD
GND
6
T100
2
1
2
1
6
7
VCC_OUT
2
1
CCFL inverter
4
PR
2
1
VCC_OUT
VCC 16
GND
10
PR
rev. 1.0 - 12/2009
TOUCH
SCREEN
Service Manual
075.1
Display board - board 1 (2994502X)
10-7
[1] SPI_TOUCH_CS
[1] SPI_MPLEX_CS1
[1] SPI_MPLEX_CS2
[1] SPI_ADC_DATA_OUT
[1]
SPI_CLK
GND
CO200
100nF
+3.3V
GND
G1
G2A
G2B
CO210
100nF
R203
10K
6
4
5
A
B
C
R202
10K
1
2
3
+3.3V
R201
10K
+3.3V
R200
10K
+3.3V
+3.3V
16
VCC
GND
GND
15
14
13
12
11
10
9
7
U200
74HC138
Y0
Y1
Y2
Y3
Y4
Y5
Y6
Y7
SPI_KEYBOARD_CS
11
3.3
10
U104E
74HC14_3
10
13
12
11
OE
SLOAD
RCK
SCK
QH
A
B
C
D
E
F
G
H
GND
14
15
1
2
3
4
5
6
7
U210
74HC589
SER
+3.3V
GND
R210
10K
GND
R211
10K
GND
Keyboard readout
16
VCC
GND
10-8
8
SPI Chip Select

demultiplexer
GND
R212
10K
R213
10K
+3.3V
JST4
1
2
3
4
J210
Key
board
075.1
Service Manual
Display board - board 2 (2994502X)
rev. 1.0 - 12/2009
Service Manual
075.1
JST4
1
2
3
4
J100
Display
board
Keyboard (2994508D)
SW102
CLEAR
SW101
STOP
SW100
START
rev. 1.0 - 12/2009
10-9
075.1
Service Manual
Motor relay board - 230V (2975500D)

J1
1
2
3
D1
1N4004
D2
1N4004
4
5
6
7
D3
S1
SW DPST
RE1
12V
D4
RE2
12V
8
CON8
T1
51
R3
C2
33R
10nF
J3
R1
C1
100R
100nF/1250V
230V
T2
55
S2
JST7
T3
52
"BLEEDER"
R2
10K/2W
J2
72
T4
73
124
74
T5
54
10-10
rev. 1.0 - 12/2009
Service Manual
075.1
Motor relay board 115V (2975540V)

J1
1
2
3
D1
D2
1N4004
1N4004
4
5
6
7
D4
D3
S1
RE1
12V
12V
RE2
CON8
SW DPST
T1
51
R3
C2
33R
10nF
J3
R1
C1
100R
100nF/1250V
3
115V
4
5
T2
55
JST7
S2
T3
52
"BLEEDER"
R2
10K/2W
J2
72
T4
73
124
74
T5
54
rev. 1.0 - 12/2009
10-11
10-12
Connection board
1
2
3
4
5
JST5
J101
FRAME
3
NC
NC
6
A
B
4
1
GND
5
GND
U100
SN65220DBVR
GND 2
GND
1
2
3
4
DD+
GND
S2
PC
FRAME
J100
Kycon KUSB-SMT-BS1N-W
V+
S1 5
075.1
Service Manual
Connection board - regular (2992003U)
rev. 1.0 - 12/2009
GND
MOD_VCC
MOD_RxD
MOD_TxD
MOD_CTS
MOD_RTS
MOD_RESETn
MOD_MUTE
FIF_RxD
FIF_TxD
JST12
1
2
3
4
5
6
7
8
9
10
11
12
GND
+3.3V
R108
180R
R103
180R
GND
C105
100nF
C103
100nF
V+
C2-
C2+
C107
100nF
CASE
H101
4.0 mm
GND
C111
100nF
+3.3V
C118
47pF
H102
4.0 mm
R107
4K7
R102
4K7
15
10
13
12
GND
C119
47pF
H104
4.0 mm
C106
100nF
C104
100nF
GND
R111 4K7
GND
H103
4.0 mm
V-
C1-
C1+
EN
T1IN
T2IN
GND
CO103
100nF
R1OUT
R2OUT
GND
SHDN
T1OUT
T2OUT
R1IN
R2IN
+3.3V
GND
20
17
8
16
9
IC103
MAX3222E
R112 4K7
Mounting holes
GND
CO108
100nF
19
VCC
GND
18
J108
+3.3V
C113
100nF
GND
2 BP
3 + V-
GND
GND
IC102
LM4818
CO102
100nF
L1
L2
+3.3V
R104
470k
4 1 SD V+
C120
100nF
R105
470k
6
7
GND
LS101
41.T70P015H
C108
100nF
GND
R110
4k7
GND
CO101
100nF
+3.3V
CON9
1
2
3
4
5
6
7
8
9
J112
CON9
1
2
3
4
5
6
7
8
9
J113
43
42
41
40
39
38
37
36
35
34
33
64
63
62
61
60
59
58
57
56
LED_DCD
LED_RX
LED_DTR
LED_TX
GND
MIC+
MICRESET
TCLK
RCLK
TX+
TXRX+
RX-
Phone_Tip
Phone_Ring
MOD100
SOCKET MODEM
SPK+
SPKGND
DTR
DCD
CTS
DSR
RI
TxD
RxD
RTS
SPKR
AGND
MICV
VCC
LED_SPD
LED_COL
LED_LINK
LED_ACT
LED_FDX
1
2
3
4
5
6
7
8
9
JST5
1
2
3
4
5
CASE
CON9
J111
1
2
J109
CON2
J105
29
30
31
32
26
22
23
24
11
12
4
5
6
7
1
2
C114
C115
C116
C117
B103
B105
B104
B106
GND
47pF
47pF
47pF
47pF
BEAD
BEAD
BEAD
BEAD
D101
SMTPA220
R121
4R7
NC
NC
R122
4R7
CASE
GND
GND
R109
180R
F101
TRF600-150
IC104
SN65220DBVR
GND 2
JST4
1
2
3
4
J103
R123
4R7
C123
CASE
1nF/1kV
C122
1nF/1kV
R120
4R7
6
A
B
rev. 1.0 - 12/2009

4
+3.3V
S2
S1
1
6
2
7
3
8
4
9
5
J106
USB Device
V+
DD+
GND
J107
FIF connector
1
2
3
4
10
CASE
CASE
11
10
RJ45 Connector
1
2
3
4
5
6
7
8
J104
J102
RJ11 Connector
6
5
4
3
2
1
Service Manual
075.1
Connection board - expanded (2992001S)
10-13
H1
4.0 mm
H2
4.0 mm
B101
B102
B103
B104
B105
H3
4.0 mm
BEAD
BEAD
BEAD
BEAD
BEAD
Mounting holes
JST3
1
2
3
J101
CASE
NM
GND
C112 47pF NM
R106 1K
H4
4.0 mm
27R
R109
R112
10K
R101
0R
PB4
[2]
C101
100F
Low ESR
C102
100nF
R107
R108
GND
1R
1R
(Remark: the ring is open on the

side opposite of the side of all
the JST connectors).
GND
VCC
Sense
D Col
TCap
Comp
S Em
S Col
TP101 GND
TP102 GND
GND
IC101
MC34063A
CASE is implemented as a guard ring

of 3mm on all layers. The ring is
'stitched' together by vias placed
on every 4 mm.
GND
TP106
GND
74LVC14A
IC204E
10
11
G100 GNDSTER
F101
MF-SM050
NM
TP105
+24V
+24V_INT
GND
+3.3V
14
74LVC11
GND
VCC
IC201D
R102
470R
14
C103 47pF
C113 47pF
C114 47pF
74LVC14A
GND
VCC
IC204G
R103
470R
14
74LVC14A
GND
VCC
IC405G
R105
470R
STPS1L40A
R104
470R
GND
D101
L102
220H
Power of logic gates devices
1
2
14
C104
74LVC32
GND
VCC
IC407E
GND
100nF
C105
220F
Low ESR
GND
GND
100nF
C109
+5V
VIN
VIN
IC103
C106
100nF
IC102
D102
STPS1L40A
2
4
GND
VOUT
CASE
2
4
LD1117_25/SOT223
GND
VOUT
CASE
LD1117_33/SOT223
GND
1
10-14
GND
GND
C110
100nF
GND
C107
100nF
GND
C111
100F
Low ESR
+2.5V
GND
C108
100F
Low ESR
+3.3V
075.1
Service Manual
Communication board - Power supply (2992000R)
rev. 1.0 - 12/2009
EP_RST
[4]
nRESET
[3,5]
GND
CO200_7
100nF
CO200_6
GND
100nF
10nF
100nF
10nF
CO200_5
100nF
VDDIO
GND
CO201
CO200_3
10nF
CO200_8
100nF
CO203
JTAG Debug Port
+3.3V
1
3
5
7
9
11
13
15
17
19
74LVC32
100nF
CO200_9
100nF
CO204
J201
HEADER 10X2
NM
10
IC407C
IC204B
74LVC14A
TDO
nSRST
R250 10K
R251 10K
R252 10K
R253 10K
R254 10K
nTRST
TDI
TMS
TCLK
10nF
100nF
GND
VDDIO
10nF
100nF
CO200_13
B202
B201
+2.5V
10nF
TDO
TRST
TDI
TMS
TCLK
TEST1
TEST0
DSR1
DCD1
CTS1
TXD1
RXD1
TXD2
RXD2
PHDIN
LEDDRV
RUN/CLKEN
EXPRDY
EXPCLK
URESET
POR
BATOK
EXTPWR
WAKEUP
PWRFL
BATCHG
MEDCHG/BROM
XTAL32OUT
XTAL32IN
XTALOUT
XTALIN
VCORE
GND
GND
100nF
CO200_1
VOSC
VOSC
CO200_14
BEAD
BEAD
22
125
11
58
90
39
40
R216
10K
38
37
35
32
36
EP_nRXF
EP_HOST
EP_nTXE
EP_TXD
EP_RXD
9
10
FIF_TXD
FIF_RXD
R212
[4]
[4]
R210
R211
R208
R209
49
7
8
4
156
154
10K
153
10K
152
WAKEUP 161
10K
162
10K
151
155
10K
34
31
10K
IC204A
74LVC14A
R207
50
159
158
R201
27R
[4]
[4]
[4]
[4]
[4]
GND
+3.3V
+3.3V
GND
+3.3V
+3.3V
C209
10nF
R204 10K
10pF
C201
CO200_12
BEAD
BEAD
GND
C208
10nF
CO200_11
B204
B203
+3.3V
CO200_10
GND
IC201C
74LVC11
R255 10K
R256 10K
R257 10K
9
10
11
R203 10K
WAKEUP
X201
3.6864 MHz
74LVC14A
Test Interface
GND
100nF
C207
2
4
6
8
10
12
14
16
18
20
74LVC14A
IC204D
9
+3.3V
74LVC14A
IC204F
13
12
nFMRST
GND
R202 10K
10pF
C202
C205
47pF
Serial I/O
VCORE
RESET
[4,5]
[4] EP_BOOTSEL
IOCHRDY
[5]
C214
100nF
CO200_4
F3686KHZ
ADCOUT
ADCIN
ADCCS
ADCCLK
SMPCLK
EXTFIQ
EINT1
EINT2
EINT3
IRQs
IC200A
PA0
PA1
PA2
PA3
PA4
PA5
PA6
PA7
PB0
PB1
PB2
PB3
PB4
PB5
PB6
PB7
LEDFLSH/PD0
PD1
PD2
PD3
PD4
PD5
BOOTSEL0/PE0
BOOTSEL1/PE1
CLKSEL/PE2
DRIVE0
DRIVE1
FB0
FB1
SCLK/PCMCLK/SSICLK
SDOUT/PCMOUT/SSITXDA
SDIN/PCMIN/SSIRXDA
LRCK/PCMSYNC/SSITXFR
MCLKIN/SSIRXFR
MCLKOUT/BUZ
SSI2 DAI Codec
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSCORE
VSSCORE
VSSRTC
VSSOSC
[4]
2
21
57
74
89
107
123
139
167
183
197
72
181
51
157
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDCORE
VDDCORE
VDDRTC
VDDOSC
General Purpose I/O
10nF
CO200_2
Place beads B201 to

B204 close to EP7312
EP7312 Main
3
12
33
64
73
81
98
108
116
124
140
149
168
174
182
190
198
203
71
180
48
160
VCORE VOSC
30
29
28
27
26
25
24
23
20
19
18
17
16
15
14
13
62
61
60
59
56
55
47
46
45
76
75
82
80
63
66
67
65
68
93
78
69
70
77
79
44
43
42
41
GND
R227
R228
R229
PD0
PD1
PD2
PD3
PD4
PD5
PB0
PB1
PB2
PB3
PB4
R220
R221
R222
R223
GND
10K
10K
10K
10K
10K
10K
10K
GND
PD[0-5]
+3.3V
R224 10K
R225 10K NM
R226 10K NM
+3.3V
PB[0-4]
GND
R231
R232
R233
R234
R235
R236
D201
D202
D203
D204
D205
D206
Board
Version
bits
+3.3V
470R
470R
470R
470R
470R
470R
GRN603
GRN603
GRN603
GRN603
GRN603
GRN603
R246
1K
R245 15K
R242 10K
R240 10K
R241 10K
+24V_INT
R259 10K NM
R260 10K
R261 10K
GND
nFMRST
+3.3V
JP201
RST MOD
R230 10K
1
2
3
R238 1K
NM
GND
nUSBINT [5]
nUARTINT0 [4]
nUARTINT1 [4]
LANINT [5]
+3.3V
R237
10K
R205
10K
PFO/CAL TP208
GND
+3.3V
TP205 PB5
TP206 PB6
TP207 PB7
10K
R218
TP203 SCLK
10K
TP201 SDO
TP202 SDI
R217
R258
10K
+3.3V
PD0
VDDIO
PD1
IC204C
5
PD2
PD3
IC203
PB0
PB1
PB2
PB3
PB4
PFI
GND
1
2
10
10K
10K
PB0
PB1
PB2
PB3
PB4
R248
R247
FM3104
VBAK
CNT1
CNT2
X1
X2
11
PFO/CAL
RST
A0
A1
SCL
SDA
TESTLED0
TESTLED1
TESTLED2
TESTLED3
TESTLED4
TESTLED5
3
4
13
12
+3.3V
14
VDD
R200
27R
PD4
Reset, Clock, and Power Controller

PD5
PWM
GND
rev. 1.0 - 12/2009

SSI1 ADC
Place IC204, R200, and R201 near

EP7312 and keep track length from
XTALOUT to input 5 of IC204 very
short
[4]
[4]
[4]
[4]
[1]
BT201
CR1632 (3V)
GND
X203
2 32.768 kHz
Service Manual
075.1
Communication board - CPU core (2992000R)
10-15
D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
D17
D18
D19
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31
CO301_3
10nF
100nF
100nF
GND
10nF
CO303_1
100nF
+3.3V
CO303_2
10nF
CO301_1
+3.3V
GND
CS0
CS1
CS2
CS3
CS4
CS5
HALFWORD
WORD
CO302_1
+3.3V
GND
SDCLK
SDCKE
PD6/SDQM0
PD7/SDQM1
SDQM2
SDQM3
SDCS0
SDCS1
A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
BA1/A13
BA0/A14
DRA12/A15
DRA11/A16
DRA10/A17
DRA9/A18
DRA8/A19
DRA7/A20
DRA6/A21
DRA5/A22
DRA4/A23
DRA3/A24
DRA2/A25
DRA1/A26
DRA0/A27
MOE/SDCAS
WRITE/SDRAS
MWE/SDWE
Static Memory IF
CO302_2
Keyscan Interface
IC200B
EP7312 External Bus
COL0
COL1
COL2
COL3
COL4
COL5
COL6
COL7
CL1
CL2
DD0
DD1
DD2
DD3
FRM
M
D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
D17
D18
D19
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31
LCD Interface
92
91
88
87
86
85
84
83
185
184
192
191
189
188
186
187
179
177
175
172
170
166
164
150
147
145
143
141
137
135
133
131
129
127
122
120
118
115
113
111
109
104
102
100
97
96
95
94
nCS0
nCS1
100nF
10nF
100nF
CO302_5
100nF
CO301_5
100nF
10nF
CO304_2
CO301_2
10nF
23
24
25
26
29
30
31
32
33
34
22
35
36
20
21
nSDCS0
nRD
nSDRAS
nWR
[4,5]
[5]
[4]
[4]
nCS2
nCS3
nCS4
nCS5
10nF
CO301_6
10nF
CO302_6
[4]
[5]
nCS1
[4,5]
nWR
28
41
54
100nF
CO301_7
100nF
VCC
VCC
VCC
VCCQ
VCCQ
VCCQ
VCCQ
27
14
1
49
43
9
3
2
4
5
7
8
10
11
13
42
44
45
47
48
50
51
53
+3.3V
D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
GND
nSDCS0
nRD
nSDRAS
nWR
SDCLK
SDCKE
SDQM2
SDQM3
A27
A26
A25
A24
A23
A22
A21
A20
A19
A18
A17
A16
A15
A14
A13
GND
GND
GND
VSSQ
VSSQ
VSSQ
VSSQ
CS
CAS
RAS
WE
CLK
CKE
DQML
DQMH
A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
NC/A12
BA0
BA1
VCC
VCC
VCC
VCCQ
VCCQ
VCCQ
VCCQ
DQ0
DQ1
DQ2
DQ3
DQ4
DQ5
DQ6
DQ7
DQ8
DQ9
DQ10
DQ11
DQ12
DQ13
DQ14
DQ15
IC302
MT48LC4M16/SO
or IS42S16400B-7T
28
41
54
6
12
46
52
19
17
18
16
38
37
15
39
23
24
25
26
29
30
31
32
33
34
22
35
36
20
21
SDRAM is upgradeable to from 4Mx16 to 32Mx16 devices.

Pin 36 will be NC on 4Mx16 and 8Mx16 devices, and A12
on the larger capacity devices
MT48LC4M16/SO
or IS42S16400B-7T
GND
GND
GND
VSSQ
VSSQ
VSSQ
VSSQ
CS
CAS
RAS
WE
CLK
CKE
DQML
DQMH
DQ0
DQ1
DQ2
DQ3
DQ4
DQ5
DQ6
DQ7
DQ8
DQ9
DQ10
DQ11
DQ12
DQ13
DQ14
DQ15
IC301
A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
NC/A12
BA0
BA1
CO302_7
GND
19
17
18
16
SDCLK
SDCKE
SDQM0
SDQM1
6
12
46
52
38
37
15
39
A27
A26
A25
A24
A23
A22
A21
A20
A19
A18
A17
A16
A15
A14
A13
nRD
R303 0R
Place near EP7312
CO302_4
CO304_1
CO301_4
100nF
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23
A24
A25
A26
A27
SDQM2
SDQM3
CO302_3
204
205
206
207
208
1
105
5
202
6
201
200
199
54
53
196
195
194
193
178
176
173
171
169
165
163
148
146
144
142
138
136
134
132
130
128
126
121
119
117
114
112
110
106
103
101
99
D[0..31]
+3.3V
D16
D17
D18
D19
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31
[2,5]
GND
C301
10pF
NM
R304
0R
NM
SDCLK
25
24
23
22
21
20
19
18
8
7
6
5
4
3
2
1
48
17
16
9
10
13
nRESET
AM29LV320
or M29W320DT
or MBM29DL640E
nRD 28
nCS0 26
nWR 11
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23
C302
10pF
NM
R305
0R
NM
Place termination networks

near SDRAMs
27
14
1
49
43
9
3
2
4
5
7
8
10
11
13
42
44
45
47
48
50
51
53
GND
OE
CE
WE
A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
NC
IC303
470R
R301
WP/ACC
BYTE
RESET
RY/BY
DQ0
DQ1
DQ2
DQ3
DQ4
DQ5
DQ6
DQ7
DQ8
DQ9
DQ10
DQ11
DQ12
DQ13
DQ14
DQ15
+3.3V
27
A[1..27]
Vss
37
Vcc
Vss
46
14
47
12
15
29
31
33
35
38
40
42
44
30
32
34
36
39
41
43
45
D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
R306 10K
R307 10K
+3.3V
25
24
23
22
21
20
19
18
8
7
6
5
4
3
2
1
48
17
16
9
10
13
nRD 28
nCS0 26
nWR 11
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23
GND
OE
CE
WE
A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
NC
IC304
RY/BY
14
47
12
15
D16
D17
D18
D19
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31
[4,5]
AM29LV320
or M29W320DT
or MBM29DL640E
WP/ACC
BYTE
RESET
29
31
33
35
38
40
42
44
30
32
34
36
39
41
43
45
A[1..27]
DQ0
DQ1
DQ2
DQ3
DQ4
DQ5
DQ6
DQ7
DQ8
DQ9
DQ10
DQ11
DQ12
DQ13
DQ14
DQ15
+3.3V
Vcc
37
Vss
10-16
SDRAM Interface
Vss
Data Bus
27
Address Bus
46
+3.3V
RED603
FLASH
WRITE
D302
R302
470R
D[0..31]
[4,5]
075.1
Service Manual
Communication board - CPU memory (2992000R)
rev. 1.0 - 12/2009
nWR
nCS4
nCS5
[3,5]
[3]
[3]
nUARTINT1
F3686KHZ
EP_RXD
EP_TXD
[2]
[2]
[2]
[2]
nCS1
nCS4
nCS5
EP_RST
[3]
[2]
[2] EP_BOOTSEL
nUARTINT0
[2]
D[0..31]
[3,5]
nRD
[3,5]
RESET
A[1..27]
[3,5]
[2,5]
FIF_RXD
[2]
5
4
3
D0
D1
D2
D3
D4
D5
D6
D7
1
19
2
3
4
5
6
7
8
9
74LVC32
74LVC32
IC407B
IC407A
[2]
[2]
GND
DIR
OE
18
17
16
15
14
13
12
11
BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7
A2
A3
A4
13
GND
+3.3V
R442
74LVC14A
14
13
30
29
36
10
11
19
15
28
27
26
44
45
46
47
48
1
2
3
1K
10K
10K
R441
R422
R423
R424
R425
+3.3V
10K
10K
10K
10K
10K
HW ID = 1
R417
R416
10K
R427
1K
+3.3V
R443
10K
R426
+3.3V
BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7
BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7
26
41
30
29
28
27
40
39
38
37
36
35
33
32
21
19
16
17
20
22
24
23
10
15
13
12
11
XTAL2
XTAL1
INT0
INT1
GND
SI/WUB
PWREN
RXF#
TXE#
RD
WR
FIFO D0
FIFO D1
FIFO D2
FIFO D3
FIFO D4
FIFO D5
FIFO D6
FIFO D7
CTS
DSR
RI
DCD
DTR
RTS
TXD
RXD
9
18
6
4
8
22
23
35
20
16
21
32
31
43
5
7
33
38
34
39
40
41
+3.3V
IC401
SC16C2550B
OUT1
RXRDY1
TXRDY1
RXD1
TXD1
RTS1
CTS1
DTR1
DSR1
CD1
RI1
OUT0
RXRDY0
TXRDY0
RXD0
TXD0
RTS0
CTS0
DTR0
DSR0
CD0
RI0
SI/WUA
TXDEN
SLEEP
RXLED
TXLED
RESET
CS0
CS1
RD
WR
A0
A1
A2
D0
D1
D2
D3
D4
D5
D6
D7
Hardware ID bits:
CTS = Bit 0
DSR = Bit 1
RI = Bit 2
DCD = Bit 3
BD[0-7]
+3.3V
IC405F
12
+3.3V
EP_nRXF
EP_nTXE
IC406
74LVC245
B1
B2
B3
B4
B5
B6
B7
B8
74LVC14A
IC405B
4
3
+3.3V
A1
A2
A3
A4
A5
A6
A7
A8
74LVC14A
IC405E
11
nWR
74LVC11
IC201B
nRD
D[0..31]
10
RESET
nCS5
nCS4
nWR
nRD
A[1..27]
+3.3V
42
VCC
GND
17
FIF_TXD
10K
10K
10K
GND
+3.3V
+3.3V
C402
100nF
C401
100nF
10K
R409
GND
24
28
22
23
19
18
17
16
15
14
13
12
R444
R445
R446
R447
3V3OUT
IC404
FT2232
TEST
EEDATA
EESK
EECS
RESET
XTOUT
XTIN
RSTOUT
47
48
44
43
8
7
R430 4K7
R438 4K7
R429
1K
GND
C409 10nF
C412 10nF
C411 10nF
R428
470R
GND
100nF GND
C410
1
2
3
4
93C46
CS
SK
DIN
DOUT
IC408
R433
10K
R432
4K7
24
28
R431
10K
8
7
6
5
C419
100nF
C418
47pF
VCC
NC
NC
GND
GND
GND
C406
100nF
C405
100nF
10K
22
23
19
18
17
16
15
R420
R421
R439
R440
R410
14
13
12
10K
10K
10K
10K
PB0
PB1
PB2
PB3
GND
GND
USB DM (-)
USB DP (+)
R411
470R
R406
GND
10K
R401
R402
R403
+5V
31
14
VCCIOB
VCCIOA
[2]
20
VCC
GND
42
3
VCC
VCC
GND
GND
GND
GND
34
25
18
9
10
46
AVCC
AGND
45
+3.3V
R1IN
R2IN
R3IN
R4IN
R5IN
T1OUT
T2OUT
T3OUT
+3.3V
R1IN
R2IN
R3IN
R4IN
R5IN
T1OUT
T2OUT
T3OUT
+5V
20
21
4
5
6
7
8
9
10
11
[5]
GND
100nF
C408
100nF
C407
100nF
C404
100nF
C403
100nF
100nF
CO402
F6MHZ
GND
GND
CO401
+3.3V
IC403
MAX3243/SO
27
V+
C2-
C2+
EP_HOST [2]
GND
V-
C1-
C1+
27
20
21
4
5
6
7
8
9
10
11
IC402
MAX3243/SO
V+
C2-
C2+
FORCEOFF R2OUTB
FORCEON INVALID
R1OUT
R2OUT
R3OUT
R4OUT
R5OUT
T1IN
T2IN
T3IN
V-
C1-
C1+
FORCEOFF R2OUTB
FORCEON INVALID
R1OUT
R2OUT
R3OUT
R4OUT
R5OUT
T1IN
T2IN
T3IN
10K
10K
10K
10K
26
VCC
GND
25
26
VCC
GND
rev. 1.0 - 12/2009

25
[2]
[2]
[2]
[2]
74LVC14A
IC405D
8
74LVC14A
IC405C
6
100nF
CO403
R434
R435
100nF
CO404_1
27R
27R
+5V
GND
74LVC14A
IC405A
1
2
12
BEAD
BEAD
BEAD
BEAD
BEAD
BEAD
BEAD
BEAD
BEAD
BEAD
B412
B413
B416
B417
74LVC32
IC407D
OUT
R414
470R
100nF
CO404_2
C414
47pF
NM
100nF
GND
100nF
CASE
GND
GND
+3.3V
100nF
CO407
GND
+5V
R413
10K
11
CO406
C415
47pF
R418
1K
CO405
GND
GND
IC409 OSC 6MHz

4 VCC
TS 1
13
B409
B414
B415
R415
10K
BEAD
BEAD
BEAD
B405
B406
B407
B408
BEAD
BEAD
BEAD
BEAD
B401
B402
B403
B404
B411
B410
J401
100nF
100nF
CO409
+5 Volt
DataData+
GND
SHIELD
AUX_DCD
AUX_RxD
AUX_TxD
AUX_DTR
AUX_GND
AUX_DSR
AUX_RTS
AUX_CTS
Auxilliary
Port
To
Connector
Board
100nF
CO404_3
10nF
CO404_4
USB
Device
MOD_VCC
MOD_RxD
MOD_TxD
MOD_CTS
MOD_RTS
MOD_RESETn
MOD_MUTE
FIF_RxD
FIF_TxD
FIF_CTS
FIF_RTS
GND
CO408
+5V
JST5
1
2
3
4
5
J403
JST8
1
2
3
4
5
6
7
8
J402
JST12
1
2
3
4
5
6
7
8
9
10
11
12
Service Manual
075.1
Communication board - Peripheral I/O (2992000R)
10-17
RESET
nWR
[3,4]
nCS3
[3]
nUSBINT
A[1..27]
[3,4]
nRESET
[2]
D[0..31]
[3,4]
IOCHRDY
nRD
[3,4]
[2]
nCS2
[2,4]
[3]
[2,3]
A[1..27]
D[0..31]
+3.3V
GND
10K NM
10K NM
10K NM
R503
10K NM
10K NM
R506
R507
R508
10K
R531
A3
A2
13
2
1
R530 10K
R532 10K
R533 10K
R534 10K
+3.3V
12
74LVC11
IC201A
GND
10K NM
R505
X501
20MHz
NM NM
NM
10K NM
R504
10K NM
R501
R502
R510 10K 1%
R511 10K 1%
A1
A2
A3
D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
25
26
27
28
34
29
30
31
32
21
22
23
59
60
63
64
2
3
4
5
6
7
9
10
11
12
13
14
16
17
97
98
77
76
93
2
3
4
5
6
75
63
29
28
34
49
61
62
33
64
36
7
17
37
38
39
40
41
42
43
44
45
46
47
48
50
51
52
53
54
58
59
60
DREQ1
DREQ2
DACK1
DACK2
EOT
INT1
INT2
TEST
RESET
CS
RD
WR
A0
A1
D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
IC501
+3.3V
XTAL1
XTAL2
HWSLEEP
TESTSEL
RES
ELCS
EECS
EESK
EEDATAOUT
EEDATAIN
RESET
AEN
MEMR
MEMW
MEMCS16
REFRESH
IOR
IOW
IOCS16
IOCHRDY
SBHE
CHIPSEL
CSOUT
SA0
SA1
SA2
SA3
SA4
SA5
SA6
SA7
SA8
SA9
SA10
SA11
SA12
SA13
SA14
SA15
SA16
SA17
SA18
SA19
56
VHOLD2
VHOLD1
GND
43
41
44
39
48
49
50
51
52
53
55
54
47
46
38
33
40
42
37
36
24
19
DI+
DICI+
CIDO+
DOTXD+
TXDRXD+
RXD-
DMACK0
DMACK1
DMACK2
DMARQ0
DMARQ1
DMARQ2
INTRQ0
INTRQ1
INTRQ2
INTRQ3
SD0
SD1
SD2
SD3
SD4
SD5
SD6
SD7
SD8
SD9
SD10
SD11
SD12
SD13
SD14
SD15
10K
C511 100nF
R551
R538
F6MHZ
[4]
100nF
CO500_2
8R2
R522 NM
8R2
R521 NM
10nF
CO501_2
+3.3V
R516
470R
NM
NM
[2]
R545
R546
R541
R542
CO500_3
CO500_4
10nF
NM
CO500_5
100nF
NM
27R
27R
27R
27R
C516
47pF
C514
47pF
T501
TG41-2006N
NM
10
15
GND
GND
R547 C517
15K
47pF
R543 C515
15K
47pF
GND
GND
R548
15K
R544
15K
GND
GND
CASE
+5V
CASE
+5V
GND
JST4
NM
1
2
3
4
J501
LAN
(10 Mb Ethernet)
JST6
1
2
3
4
5
6
J503
JST6
1
2
3
4
5
6
J502
+5 Volt
DataData+
GND
SHIELD
+5 Volt
DataData+
GND
SHIELD
USB Host #2
USB Host #1
OPTIONAL LAN (992006)
C505
100nF/1KV
NM
100nF
NM
CO500_7
+3.3V
GND
CO500_6
10nF
NM
C504
100nF/1KV
NM
GND
16
14
6
3
11
Place R521, R522, R523, and C501

very close to CS8900A (See Cirrus
AN83, page 44 & 45)
100nF
NM
C502
C503
100nF
100nF
NM
NM
GNDGND
R523
100R
NM
C501
560p
NM
100nF
NM
LANINT
10nF
NM
CO500_1
470R +3.3V
R515
+3.3V
GND
CO501_1
D502
NM
GRN603 ACTIVE
+3.3V
GND
10K NM
10K
NM
R512
+3.3V
D501
NM
GRN603 LINK
R513
D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
GND
78
99
100
79
80
81
82
83
84
87
88
91
92
16
14
12
15
13
11
32
31
30
35
65
66
67
68
71
72
73
74
27
26
25
24
21
20
19
18
TP501 DDTP502 DD+

10K
10K
10K
R536
R537
10K
R535
GND
C510 100nF
BSTATUS/HC1
LINKLED/HC0
LANLED
+3.3V
ISP1161A1
XTAL1
CLKOUT
XTAL2
DVBUS
DDDD+
H1DH1D+
H2DH2D+
HOC2
HOC1
HPSW2
HPSW1
GL
NDPSEL
HWAKEUP
HSUSPEND
DWAKEUP
DSUSPEND
VCC
IC500
CS8900A-CQ3
NM
8
10
23
55
57
58
VREG
1
8
15
18
35
45
62
57
+3.3V
DVSS1
DVSS1A
DVSS2
DVSS3
DVSS3A
DGND
DGND
DGND
DGND
DGND
DGND
DGND
AGND
9
22
56
69
DVDD1
DVDD2
DVDD3
DVDD4
90
85
95
AVDD1
AVDD2
AVDD3
AVSS0
AVSS1
AVSS2
AVSS3
AVSS4
DVSS4
10-18
1
89
86
94
96
70
075.1
Service Manual
Communication board - LAN and USB host (2992000R)
rev. 1.0 - 12/2009
GND
+5V
CO106
10nF
GND
+24 Volt
GND
COVER out
COVER in
Motor run relay
Motor start relay
GND
GND
Unit
power
Side
cover
Top
cover
1
2
3
1
2
3
4
5
6
7
8
R125
1K
JST8
J102
JST3
J101
JST3
1
2
3
CASE
GND
MH100
MOUNTING
HOLE
GND
GND
R111
4K7
R107
56R
R105
6K8
R102
6K8
R100
6K8
R110
4K7
GND
R108
1K
GND
R103
1K
GND
R101
1K
12
10
GND
GND
GND
11
13
U804F
74HCT14_5
U804E
74HCT14_5
C118
10nF
C111
10nF
C100
10nF
GND
GND
TP103
GND
R117
150R
R115
1K
C127
1nF
R118
8K2
R116
10K
24V_IN
TP105
+24V
GND
+5V
GND
C129
1nF
3 +
GND
R124
1K
GND
+5V
POWER_DOWN [2]
IN_START_RELAY [2]
IN_MOTOR_RELAY [2]
U106B
LM358
7
CO150
10nF
CO151
10nF
GND
C102
220F
GND
GND
CO152
10nF
CO153
100nF
CO154
100nF
CO155
100nF
R119
150R
OUTPUT
FEEDBACK
GND
GND
D100
STPS340U
L100
47H
C119
100nF
GND
C120
100nF
GND
C121
100nF
2
3
6
7
VIN
VIN
VIN
VIN
C130
100nF
C128
220F
3
VCC
R114
0R1
GND
The information contained herein is the

property of Neopost Technologies BV,
Drachten, the Netherlands. Any copying
or reproduction of this document in any
form and/or disclosure to other parties
without the express written consent of
Neopost Technologies BV is strictly
prohibited.
GND
GND
24V_IN
GND
C104
220F
+5V
GND
GND
R121
10K
C126
100nF
24V
GND
U103
79L12
VOUT
NM
+5V
TP100
GND
C113
100nF
Vin
GND
2K7
Vout
TAB
2
4
Vin
U102
LD1117/S25
GND
GND
Vout
2
4
L103
C123
100nF
2K7
L101
TAB
GND
24V
D104
12V
GND
C131
100nF
+12V
NM
TP102
+12V
C124
1nF
L104
L102
GND
C114
100F
+2.5V
GND
C108
100F
+3.3V
+12V power supply
Otto Tuil
Common Power
Code:
time: 11:49:22
2825900V
Modified: Wednesday, August 20, 2008
Drawn:
2.5V power supply
GND
C105
100nF
U101
LD1117/S33
3.3V power supply
VCC_OUT
GND
C115
100nF
AVREF
GND
C125
100F
2K7
2K7
R104
100R
Size
A3
Sheet 1
of 12
01
Rev:
Andromeda A1/DS-70 mainboard
MAIN_CURRENT [4]
TP101
-12V
Title:
C122
100nF
C144
1uF
GND
GND
-12V
GND
C106
100nF
TECHNOLOGIES BV
PO BOX 20 9200 AA DRACHTEN
DE TIJEN 3 DRACHTEN THE NETHERLANDS
TEL: +31 512 589 300 / FAX: +31 512 589 399
R120
10K
U105
MAX4376T
OUT
CURRENT MEASUREMENT
GND
-12V power supply
R112
82R
R109
82R
C110
100nF
C117
100nF
GND
D102
BAT54S
+12V
C116
100nF
GND
C109
100nF
NM
FLAG
GND
C103
100nF
IN
U100
LM2593
DELAY
5V power supply
TAB
8
VCC_OUT
Spread arround the board
to decouple VCC_OUT
C101
220F
24V
GND
IN_COLLATOR_COVER [2]
IN_SIDE_COVER [2]
IN_TOP_COVER [2]
75mSec time left

for uC after powerdown
U106A
LM358
Power down interrupt
R113
10K
24V
GND
Q100
BC817
R106
56R
COVERTRACK2
GND
COVERTRACK1
Q101
BC817
CASE
GND
F100
3A
24V_IN
24V
SD/SS
7
J100
GND
4
4
R+
1
2
5
R-
GND
5
GND
1
GND
1
GND
+
+
rev. 1.0 - 12/2009
Cover
switches
Service Manual
075.1
Main board - Common power (2825900V)
10-19
ARM_PORn
+3.3V
+3.3V
+3.3V
1
3
5
7
9
11
13
15
17
19
HEADER 10X2
J200
2
4
6
8
10
12
14
16
18
20
GND
10K
10K
10K
10K
10K
R210
R209
R208
GND
R223
10K
40
39
22
156
125
11
58
90
38
37
35
32
36
9
10
34
31
10K
10K
10K
153
152
161
162
151
155
154
10K
10K
GND
C203
100nF
+3.3V
GND
RESIN
SEN
CT
GND
C204
1uF
T=26mSec
2
7
3
+5V
U203
TL7702A
RSET
RST
REF
TEST0
TEST1
TDO
URESET
TRST
TDI
TMS
TCLK
DSR1
DCD1
CTS1
TXD1
RXD1
TXD2
RXD2
PHDIN
LEDDRV
BATOK
EXTPWR
WAKEUP
PWRFL
BATCHG
MEDCHG/BROM
POR
RUN/CLKEN
EXPRDY
EXPCLK
XTAL32IN
XTAL32OUT
XTALIN
XTALOUT
C205
100nF
GND
GND
5
6
1
3.3V supervisor
R221 10K
R224 10K
R222 10K
R211
R212
R213
R214
R215
JTAG debug port
[11] ARM_POWER_ON_RESET
GND
C200
100nF
+3.3V
ARM_WAKEUP
+3.3V
GND
R206
R205
+2.5V
GND
CO200_1 CO200_2 CO200_3 CO200_4

100nF
10nF
100nF
10nF
GND
+2.5V
IRQs
BOOTSEL0/PE0
BOOTSEL1/PE1
CLKSEL/PE2
LEDFLSH/PD0
PD1
PD2
PD3
PD4
PD5
PB0
PB1
PB2
PB3
PB4
PB5
PB6
PB7
PA0
PA1
PA2
PA3
PA4
PA5
PA6
PA7
PWM_DRIVE0
PWM_DRIVE1
FB0
FB1
SCLK/PCMCLK/SSICLK
SDOUT/PCMOUT/SSITXDA
SDIN/PCMIN/SSIRXDA
LRCK/PCMSYNC/SSITXFR
MCLKIN/SSIRXFR
MCLKOUT/BUZ
ADCOUT
ADCIN
ADCCS
ADCCLK
SMPCLK
EXTFIQ
EINT1
EINT2
EINT3
GND
GND
CO203
100nF
+5V
R231
1K
R227
1K
+3.3V
CO204
100nF
CO205
100nF
ARM_PORn [3]
LCD_RESET [12]
U200A
EP7312
Main1
47
46
45
62
61
60
59
56
55
20
19
18
17
16
15
14
13
30
29
28
27
26
25
24
23
76
75
82
80
63
66
67
65
68
93
78
69
70
77
79
44
43
42
41
10K
R204
R201
R207
R202
GND
GND
GND
GND
+5V
1
2
3
1
2
3
A0
A1
A2
A0
A1
A2
+5V
+5V
GND
OE
U204
FM24C64
R220
100R
TECHNOLOGIES BV
TEL: +31 512 589 300 / FAX: +31 512 589 399
FRAM_WP
FRAM_I2C_SCL
5
6

prohibited.
GND
WP
SCL
SDA
FRAM2_WP
R228
2K2
FRAM_I2C_SDA
U205
FM24C64
WP
SCL
SDA
R229
2K2
5
+5V
OUT
U202
GND
ARM_CORE_CLK
ARM_RTC_CLK
ARM_WAKEUP
+3.3V
TCK
TMS
TDI
TDO
SYSCLK
F3686KHZ
F32KHZ
F1024HZ
INT
CS
RD
WR
RESET
A1
A2
A3
A4
D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
J201
[6] FV_DongleCommunication
HEADER 8X1
1
2
3
4
5
6
7
8
FRAM_I2C_SDA
FRAM_I2C_SCL
DBG5
U201
LC4256V-75T100
3
4
5
8
9
10
11
6
35
36
37
R226
1K
+5V
+5V
NM
GND
R230
56R
DBG5
TP205
DBG5
J202
UCAN CLIP
D105
BAT54S
Dongle
FV_PWM_Collator [8]
IN_FINGER_SOL [6]
IN_EJECT_SOL [6]
StackerSDA [9]
StackerCLK [9]
IN_SEALING_BRUSH_SOL [6]
StackerPresent [9]
FV_DongleCommunication [6]
FV_DigClutch_FE1 [9]
FV_CollatorStopPosDir [8]
FV_DigClutch_FoReverse [6]
FV_DigClutch_FoForward [6]
FV_DigClutch_FO1 [7]
FV_DIR_Collator [8]
FV_MaxiFeeder_motor [8]
IN_MOTOR_RELAY [1]
IN_RPM_ENV_TRACK [6]
IN_SEALING_SOL [6]
FV_CollatorStopPosMotor [8]
IN_START_RELAY [1]
48
49
50
53
54
55
56
58
59
60
61
64
65
66
67
69
Otto Tuil
CPU CORE
Code:
time: 11:49:22
2825900V
Drawn:
GND
C201
+3.3V
FRAM_WP
WATER_LOW [6]
RESERVOIR_DET [6]
MAIN_PDISC [5]
FV_PDisc_Collator [8]
FV_DIG_FCEL_FE1 [9]
FV_DIG_FCEL_FE2 [9]
FV_DIG_FCEL_FE3 [9]
FV_ColStopPos1 [8]
FV_DIG_FCEL_COLL [7]
FV_DIG_FCEL_RH [10]
FV_DIG_FCEL_FO [7]
FV_SwitchMaxiFeeder [8]
FV_CurveDisc_FT1 [7]
FV_CurveDisc_FT2 [7]
IN_DIG_FCEL_CLOSER [6]
IN_DIG_FCEL_ENV_TRACK [5]
POWER_DOWN [1]
FV_ColStopPos2 [8]
62
77
12
14
15
16
17
19
20
21
22
23
27
28
29
30
31
34
CPLD
In circuit
programming
connection
PWM0
PWM1
PWM2
PD0
PD1
PD2
PD3
PD4
PD5
PD6
PD7
PC0
PC1
PC2
PC3
PC4
PC5
PC6
PC7
PC8
PC9
PC10
PC11
PC12
PC13
PC14
PC15
PB0
PB1
CAP0/INT0/PA0
CAP1/INT1/PA1
INT2/PA2
INT3/PA3
PA4
PA5
PA6
PA7
PA8
PA9
PA10
PA11
PA12
PA13
PA14
PA15
GPIO CPLD
GND
Size
A3
Sheet 2
of 12
01
Rev:
10nF
GND
GND
Title:
24
52
2
74
89
44
43
42
41
88
38
39
47
[3]
nCS2
[3,10,11,12] nRD
[3,11,12]
nWR
[3]
ARM_PORn
78
79
80
81
84
85
86
87
91
92
93
94
97
98
99
100
70
71
72
73
BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7
BD8
BD9
BD10
BD11
BD12
BD13
BD14
BD15
A1
A2
A3
A4
OSC. 14.7456Mhz
A[0..27]
+3.3V
[3,12]
[3,10,11,12] BD[0..15]
2X8 Kbyte FRAM
FV_ReadHead_S2 [10]
FV_ReadHead_S3 [10]
IN_TOP_COVER [1]
IN_SIDE_COVER [1]
IN_COLLATOR_COVER [1]
IN_RPM_STACKER [6]
LCD_ENABLE [12]
SI62_LCD_CD [12]
SI62_LCD_OE [12]
SPI_MPLEX_CS2 [12]
ADC_MUL[0..5] [4]
RH_ADC_START [10]
HCF_DETECT [9]
FV_ReadHead_S0 [10]
FV_ReadHead_S1 [10]
SPI1_ADC_CS [4]
SPI1_DAC_CS [4]
SPI_MPLEX_CS1 [12]
10K
10K
10K
32bits BOOTMEM
ADC_MUL0
ADC_MUL1
ADC_MUL2
ADC_MUL3
ADC_MUL4
ADC_MUL5
R216
R218
R217
GND
TP200
WINDOW
10K
10K
10K
10K
R232
SPI1_CLK [4,12]
SPI1_DAC_DAT [4,12]
SPI1_ADC_DAT [4,12]
R244
10K
+3.3V
R243
10K
+3.3V
R242
10K
+3.3V
CO200_5 CO200_6 CO200_7 CO200_8 CO200_9 CO200_10 CO200_11 CO200_12 CO200_13 CO200_14 CO200_15
100nF
10nF
100nF
10nF
100nF
10nF
100nF
10nF
100nF
10nF
100nF
+3.3V
ARM CORE
CO201_1 CO201_2 CO201_3 CO201_4 CO201_5 CO201_6 CO201_7 CO201_8 CO201_9 CO201_10 CO202
100nF
10nF
100nF
10nF
100nF
10nF
100nF
10nF
100nF
10nF
10nF
+3.3V
TXD2
RXD2
[11]
USB_RXF#
[11] USB_HOST_CON
[11]
USB_TXE#
[11]
TXD1
[11]
RXD1
[11]
[11]
[11] ARM_BOOT_MODE
[3]
+3.3V
R203
10K
+3.3V
10K
R200
7
8
4
50
49
470R
R241
ARM_RTC_CLK
158
159
470R
R240
ARM_CORE_CLK
+3.3V
2
21
57
74
89
107
123
139
167
183
197
72
181
51
157
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDIO
VDDCORE
VDDCORE
VDDRTC
VDDOSC
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSIO
VSSCORE
VSSCORE
VSSRTC
VSSOSC
VCC
GND
8
VCC
GND
4
8
VCC
Test Interface
GND
Serial I/O
4
SSI2 DAI Codec
3
12
33
64
73
81
98
108
116
124
140
149
168
174
182
190
198
203
71
180
48
160
4
VDD
GND
2
13
25
33
40
45
63
75
83
90
95
VCC
VCC
VCC
VCC
VCC
VCC
VCC
VCC
VCC
VCC
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
Reset, Clock, and Power Controller

1
7
18
26
32
46
51
57
68
76
82
96
General Purpose I/O
PWM
10-20
SSI1 ADC
1
075.1
Service Manual
Main board - CPU core (2825900V)
rev. 1.0 - 12/2009
[12]
nCS4
[12]
nCS5
[2,10,11,12] nRD
GND
CO303
10nF
COL0
COL1
COL2
COL3
COL4
COL5
COL6
COL7
CL1
CL2
DD0
DD1
DD2
DD3
FRM
M
11
10
9
GND
CO304
10nF
+3.3V
12
U304A
74LCX11
R320
1
2
13
92
91
88
87
86
85
84
83
185
184
192
191
189
188
186
187
D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
D17
D18
D19
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31
Keyscan Interface
GND 10K
R310
470R
R300
470R
[11]
nCS1
[2]
nCS2
[10,12] nCS3
GND
D301
RED
TP301
TST2
D300
GREEN
TP300
TST1
LCD_CL1
LCD_CL2
LCD_DD0
LCD_DD1
LCD_DD2
LCD_DD3
LCD_FRM
179
177
175
172
170
166
164
150
147
145
143
141
137
135
133
131
129
127
122
120
118
115
113
111
109
104
102
100
97
96
95
94
CO305
10nF
74LCX11
U304C
3
4
5
U304B
74LCX11
D[0..31]
SDQM2
SDQM3
A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23
A24
A25
A26
A27
nCS0
U305A
74LVC32
204
205
206
207
208
1
105
5
202
6
201
200
199
54
53
196
195
194
193
178
176
173
171
169
165
163
148
146
144
142
138
136
134
132
130
128
126
121
119
117
114
112
110
106
103
101
99
CO306
10nF
U200B
EP7312
CS0
CS1
CS2
CS3
CS4
CS5
HALFWORD
WORD
MOE/SDCAS
WRITE/SDRAS
MWE/SDWE
SDCLK
SDCKE
PD6/SDQM0
PD7/SDQM1
SDQM2
SDQM3
SDCS0
SDCS1
A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
BA1/A13
BA0/A14
DRA12/A15
DRA11/A16
DRA10/A17
DRA9/A18
DRA8/A19
DRA7/A20
DRA6/A21
DRA5/A22
DRA4/A23
DRA3/A24
DRA2/A25
DRA1/A26
DRA0/A27
ARM CORE
GND
R315
470R
D8
D9
D10
D11
D12
D13
D14
D15
GND
R314
470R
D0
D1
D2
D3
D4
D5
D6
D7
23
24
25
26
29
30
31
32
33
34
22
35
36
20
21
[2,10,11,12]
[2,11,12]
[11]
[2]
[10,12]
[12]
[12]
GND
GND
GND
GND
VSSQ
VSSQ
VSSQ
VSSQ
CS
CAS
RAS
WE
CLK
CKE
DQML
DQMH
A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
NC/A12
BA0
BA1
1
19
2
3
4
5
6
7
8
9
1
19
2
3
4
5
6
7
8
9
GND
DIR
OE
A1
A2
A3
A4
A5
A6
A7
A8
B1
B2
B3
B4
B5
B6
B7
B8
18
17
16
15
14
13
12
11
18
17
16
15
14
13
12
11
U306
74LVC245
B1
B2
B3
B4
B5
B6
B7
B8
U303
74LVC245
+3.3V
GND
DIR
OE
A1
A2
A3
A4
A5
A6
A7
A8
+3.3V
VCC
VCC
VCC
VCCQ
VCCQ
VCCQ
VCCQ
DQ0
DQ1
DQ2
DQ3
DQ4
DQ5
DQ6
DQ7
DQ8
DQ9
DQ10
DQ11
DQ12
DQ13
DQ14
DQ15
MT48LC4M16/SO
or IS42S16400B-7T
28
41
54
6
12
46
52
19
17
18
16
SDCLK
SDCKE
SDQM0
SDQM1
nSDCS0
nRD
nSDRAS
nWR
38
37
15
39
A27
A26
A25
A24
A23
A22
A21
A20
A19
A18
A17
A16
A15
A14
A13
U300
BD8
BD9
BD10
BD11
BD12
BD13
BD14
BD15
BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7
27
14
1
49
43
9
3
2
4
5
7
8
10
11
13
42
44
45
47
48
50
51
53
BD[0..15]
+3.3V
D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
SDRAM LS-WORD
DATABUS buffer
nRD
nWR
nCS1
nCS2
nCS3
nCS4
nCS5
R311 1R
Place near EP7312
A[0..27]
[2,10,11,12]
GND
GND
GND
VSSQ
VSSQ
VSSQ
VSSQ
CS
CAS
RAS
WE
CLK
CKE
DQML
DQMH
A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
NC/A12
BA0
BA1
VCC
VCC
VCC
VCCQ
VCCQ
VCCQ
VCCQ
DQ0
DQ1
DQ2
DQ3
DQ4
DQ5
DQ6
DQ7
DQ8
DQ9
DQ10
DQ11
DQ12
DQ13
DQ14
DQ15
27
14
1
49
43
9
3
2
4
5
7
8
10
11
13
42
44
45
47
48
50
51
53
+3.3V
D16
D17
D18
D19
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31
GND

prohibited.
C300
33pF
NM
R312
10K
NM
SDCLK
[2]
25
24
23
22
21
20
19
18
8
7
6
5
4
3
2
1
48
17
16
9
10
13
100nF
GND
14
47
12
15
29
31
33
35
38
40
42
44
30
32
34
36
39
41
43
45
CO301_2
10nF
CO300_2
10nF
CO302_2
470R
R330
U302
S29AL016D
WP/ACC
BYTE
RESET
RY/BY
DQ0
DQ1
DQ2
DQ3
DQ4
DQ5
DQ6
DQ7
DQ8
DQ9
DQ10
DQ11
DQ12
DQ13
DQ14
DQ15
10nF
CO301_4
10nF
CO300_4
10nF
CO308_2
100nF
CO301_5
100nF
CO300_5
R305 10K
R306 10K
+3.3V
25
24
23
22
21
20
19
18
8
7
6
5
4
3
2
1
48
17
16
9
10
13
nRD 28
nCS0 26
nWR 11
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23
Otto Tuil
CPU Memory
Code:
10nF
CO301_6
10nF
14
47
12
15
29
31
33
35
38
40
42
44
30
32
34
36
39
41
43
45
D16
D17
D18
D19
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31
100nF
CO301_7
100nF
CO300_7
U308
S29AL016D
WP/ACC
BYTE
RESET
RY/BY
DQ0
DQ1
DQ2
DQ3
DQ4
DQ5
DQ6
DQ7
DQ8
DQ9
DQ10
DQ11
DQ12
DQ13
DQ14
DQ15
CO300_6
GND
OE
CE
WE
A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
NC
+3.3V
time: 11:49:22
2825900V
Drawn:
100nF
CO301_3
100nF
CO300_3
100nF
CO308_1
D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
[2,12]
FLASHROM MS-WORD
A[0..27]
10nF
CO301_8
10nF
D303
RED
FLASH
WRITE
R304
470R
CO300_8
+3.3V
Size
A3
Sheet 3
of 12
01
Rev:
100nF
Title:
10nF
CO301_1
+3.3V
GND
100nF
CO300_1
+3.3V
GND
GND
OE
CE
WE
A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
NC
CO302_1
+3.3V
ARM_PORn
nRD 28
nCS0 26
nWR 11
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23
+3.3V
FLASHROM LS-WORD
TECHNOLOGIES BV
TEL: +31 512 589 300 / FAX: +31 512 589 399
C301
33pF
NM
R313
10K
NM
Place termination networks

near SDRAM
MT48LC4M16/SO
or IS42S16400B-7T
28
41
54
6
12
46
52
19
17
18
16
38
37
15
39
23
24
25
26
29
30
31
32
33
34
22
35
36
20
21
U301
SDRAM MS-WORD
GND
nSDCS0
nRD
nSDRAS
nWR
SDCLK
SDCKE
SDQM2
SDQM3
A27
A26
A25
A24
A23
A22
A21
A20
A19
A18
A17
A16
A15
A14
A13
Vcc
37
Vss
27
Vcc
37
Vss
D[0..31]
Vss
46
[12]
[12]
[12]
[12]
[12]
[12]
[12]
D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
D17
D18
D19
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31
20
VCC
GND
10
20
Static Memory IF
VCC
LCD Interface
GND
Vss
rev. 1.0 - 12/2009
SDRAM Interface
27
Data Bus
46
Address Bus
10
Service Manual
075.1
Main board - CPU memory (2825900V)
10-21
SPI1_ADC_CS
SPI1_ADC_DAT
SPI1_CLK
SPI1_DAC_DAT
SPI1_DAC_CS
[9] FV_OFFSET_FE1
[9] FV_OFFSET_FE2
[9] FV_OFFSET_FE3
[2]
[2,12]
[2,12]
[2,12]
[2]
CO406
100nF
REF
DIN
CS
SCLK
DOUT
LDAC
C402
100nF
3.98V
13
11
12
14
GND
DAC-A
DAC-B
DAC-C
DAC-D
DAC-E
DAC-F
DAC-G
DAC-H
U403
MAX5258
GND
GND
CO401
10nF
+5V
GND
R426
39K
R423
10K
+5V
CO405
100nF
REF
CO402
10nF
C403
100nF
GND
CO404
10nF
DIN
CS
SCLK
DOUT
LDAC
3.98V
13
11
12
14
DAC-A
DAC-B
DAC-C
DAC-D
DAC-E
DAC-F
DAC-G
DAC-H
+5V
6
5
8
9
10
11
12
13
14
15
0
1
2
3
4
5
6
7
7
U406B
LM358
D402
BAT54S
Chan
2
Chan
1
16 Chan
15 Chan
Chan
7
Chan
8
Chan
9
10 Chan
+5V
D401
BAT54S
Chan
2
Chan
1
16 Chan
15 Chan
Chan
7
Chan
8
Chan
9
10 Chan
GND
R438
1K
U405
MAX5258
Photocel DAC2
GND
R413
39K
R410
10K
+5V
CO403
100nF
Photocel DAC1
GND
R460
10K
VDD
GND
VDD
GND
GND
R404
10K
R403
4K7
GND
R432
1K
R430
1K
R428
1K
R425
1K
R422
1K
R420
1K
R418
1K
R416
1K
R411
1K
R408
1K
R406
1K
CO400_1
10nF
1
6
7
CS
DOUT
CLK
GND
CO400_3
1uF
R401
56R
GND
U400
LTC1197
+IN
VREF
-IN
R402
56R
GND
R433
1R
R434
1R
R437
4K7
R431
82R
R429
82R
R427
82R
R424
82R
R421
82R
R419
82R
R417
82R
R415
82R
R409
82R
R407
82R
R405
82R
+5V
-12V
IN_TX_CLOSER [6]
IN_TX_EXIT [5]
IN_TX_LOC [6]
IN_TX_FLAP [5]
IN_TX_ENV_TRACK [5]
FV_TX_Folder [7]
FV_TX_ReadHead [7]
FV_TX_Collator [8]
C404
10nF
R435
100K

prohibited.
GND
INH
13
14
15
12
1
5
2
4
Title:
U401
74HCT4051
X0
X1
X2
X3
X4
X5
X6
X7
TECHNOLOGIES BV
TEL: +31 512 589 300 / FAX: +31 512 589 399
Uout = 11 x I photocell
Current measurement
1
U406A
LM358
Q411
BC817
Q410
BC817
Q409
BC817
Q408
BC817
Q407
BC817
Q406
BC817
Q405
BC817
Q404
BC817
Q402
BC817
FV_TX_Feeder3 [9]
FV_TX_Feeder2 [9]
FV_TX_Feeder1 [9]
ADC_MUL3
ADC_MUL4
ADC_MUL5
R450
1K
A
B
C
GND
GND
R452
1K
R451
1K
11
10
9
11
10
9
A
B
C
GND
INH
A
B
C
+5V
GND
13
14
15
12
1
5
2
4
R440
2K2
U404
74HCT4051
X0
X1
X2
X3
X4
X5
X6
X7
Otto Tuil
ANALOG I/O
Code:
Chan
Chan
Chan
Chan
Chan
Chan
Chan
Chan
Chan
Chan
Chan
Chan
Chan
Chan
Chan
Chan
14
15
16
17
18
19
20
21
6
7
8
9
10
11
12
13
0
1
2
3
4
5
time: 11:49:22
2825900V
Modified: Wednesday August 20 2008
Drawn:
INH
13
14
15
12
1
5
2
4
U402
74HCT4051
X0
X1
X2
X3
X4
X5
X6
X7
Chan
Chan
Chan
Chan
Chan
Chan
IN_ANA_RX_FLAP [5]
IN_ANA_RX_EXIT [5]
IN_ANA_RX_LOC [5]
IN_ANA_RX_CLOSER [6]
MAIN_CURRENT [1]
FV_MaxiFeeder23Detect [8]
FV_ANA_RX_Collator [7]
FV_ANA_RX_ReadHead [10]
FV_ANA_RX_Folder [7]
IN_ANA_RX_ENV [5]
FV_ANA_RX_Feeder1 [9]
FV_ReadHead_ANA0 [10]
FV_DFC_FE1 [9]
FV_DFC_FE2 [9]
FV_DFC_FE3 [9]
GND
D400
BAT54S
+2.5V
Size
A3
Sheet 4
of 12
01
Rev:
+5V
GND
C400
100nF
2,5 Volt
GND
11
10
9
Analog multiplexer
GND
2
5
3
AVREF
ADC_MUL0
ADC_MUL1
ADC_MUL2
+5V
Q401
BC817
R436
4K7
3
Q400
BC817
3 +
GND
Current Sink
GND
CO400_2
100F
R400
56R
+5V
8
VCC
GND
4
16
VCC
GND
8
10 bit ADC
1
1
1
1
1
1
1
1
1
GND
8
1
1
16
VCC
GND
8
VCC
16
[2] ADC_MUL[0..5]
10-22
GND
075.1
Service Manual
Main board - analog I/O (2825900V)
rev. 1.0 - 12/2009
GND
+5V
CO500
100nF
JST5
GND
VCC_OUT
VCC_OUT
VCC_OUT
VCC_OUT
VCC_OUT
GND
CO502
10nF
+3.3V
VCC_OUT
CO501
10nF
+3.3V
EXIT RX
EXIT TX
J502
1
2
3
4
5
JST11
1
2
3
4
5
6
7
8
9
10
11
J500
Exit
photocell
LOC RX
FLAP RX
FLAP TX
ENV_TRACK RX
ENV_TRACK TX
Enveloppe
Track
photocells
GND
R521
1K
U500B
LM358
IN_TX_EXIT [4]
IN_TX_FLAP [4]
IN_TX_ENV_TRACK [4]
+
+
GND
1K
R520
13
TP503
EXIT
NM
R515
8K2
dist: 69mm
R513
4K7
TP502
LOC
NM
GND
R511
470R
dist: 56mm
R522
470R
TP501
FLAP
NM
GND
GND
74LVC14
U502F
12
3.3
GND
R514
10K
GND
R512
10K
3 +
R510
10K
R509
1K
+5V
GND
R500
10K
R506
8K2
TP500
ENV
NM
R501
2K2
C502
1nF
dist: 9mm
R508
1K
dist: 27mm
8
4
rev. 1.0 - 12/2009
C505
10nF
C504
10nF
C503
10nF
U500A
LM358
R507
68K
C500
10nF
IN_ANA_RX_EXIT [4]
IN_ANA_RX_LOC [4]
IN_ANA_RX_FLAP [4]
[2]

prohibited.
IN_DIG_FCEL_ENV_TRACK
IN_ANA_RX_ENV [4]
MAIN_PDISC
TECHNOLOGIES BV
TEL: +31 512 589 300 / FAX: +31 512 589 399
[2]
GND
C501
33pF
U502A
74LVC14
2 3.3 1
R505
10K
R503
4K7
+3.3V
R504
150R
GND
VCC_OUT
JST5
1
2
3
4
5
J501
Main
PulsDisc
Otto Tuil
Code:
time: 11:49:22
2825900V
INSERTER PHOTOCELLS
Size
A3
Sheet 5
of 12
01
Rev:
NM
TP505
PDSC
Drawn:
+3.3V
R502
470R
D500
GREEN
Title:
Service Manual
075.1
Main board - Inserter photocells (2825900V)
10-23
CO600
10nF
GND
+5V
1
2
3
4
5
6
1
2
3
4
5
6
7
8
JST8
J603
JST6
J601
JST10
1
2
3
4
5
6
7
8
9
10
J600
CO601
10nF
CO605
100nF
Data
Gnd
JST2
1
2
J650
Electronic
ID tag
Sealing brush sol
TX closer
TX loc-cel
Eject solenoid
LOC_A1
TX closer
TX loc-cel
Eject solenoid
LOC
finger sol.
RPM FoForward
RPM FoReverse
RPM stracker
RPM env. track
GND
24V
24V
O1
O2
O3
O4
O5
O6
O7
R650
56R
C650
33pF
GND
I1
I2
I3
I4
I5
I6
I7
D600
12V
GND
1
2
3
4
5
6
7
GND
R600
56R
24V
Q600B
SI4946EY
D605
STPS340U
Q601A
SI4946EY
24V
GND
GND
R607
56R
U601A
74HCT14_5
5 1
GND
R620
1K
U600F
74HCT14_5
12
5 13
U600E
74HCT14_5
10
5 11
U600D
9 74HCT14_5
U600C
5 74HCT14_5
R608
56R
C608
10nF
GND
GND
C606
10nF
R631
150R
U600B
3 74HCT14_5
Q630
BC817
GND
D603
STPS340U
C603
220F
U600A
1 74HCT14_5
R630
10K
GND
C600
100nF
C602
10nF
U602
ULN2003L
24V
GND
GND
VCC_OUT
VCC_OUT
Q600A
SI4946EY
D601
STPS340U
16
15
14
13
12
11
10
COM
GND
Rear
side
actuators
7
8
7
U605B
LM358
[2]
FV_DongleCommunication [2]
IN_SEALING_BRUSH_SOL [2]
IN_TX_CLOSER [4]
IN_TX_LOC [4]
IN_EJECT_SOL [2]
IN_FINGER_SOL [2]
FV_DigClutch_FoForward [2]
FV_DigClutch_FoReverse
IN_RPM_STACKER [2]
IN_RPM_ENV_TRACK [2]

prohibited.
TECHNOLOGIES BV
TEL: +31 512 589 300 / FAX: +31 512 589 399
[2] RESERVOIR_DET
[2] WATER_LOW
[2] IN_SEALING_SOL
[2] IN_DIG_FCEL_CLOSER
[4] IN_ANA_RX_CLOSER
+5V
+
-
GND
C609 100nF
C610 100nF
R613
10K
R612
10K
Q601B
SI4946EY
D604
STPS340U
VCC_OUT
GND
R610 10K
R611 10K
+3.3V
24V
JST4
1
2
3
4
J604
JST4
1
2
3
4
J602
WATER
LEVEL
CLOSER
Sealing solenoid
RX closer
Otto Tuil
Code:
INSERTER POWER I/O
time: 11:49:22
2825900V
Size
A3
Sheet 6
of 12
01
Rev:
R609
56R
R605
1K
C604
1nF
R615
8K2
dist: 33mm
24V
GND
GND
C607
10nF
GND
R604
8K2
R606
1K
GND
R602
8K2
TP600
CLOSER
NM
Drawn:
R601
10K
GND
U605A
LM358
R603
68K
C601
10nF
U601B
74HCT14_5
3 5
4
Title:
8
4
24V
1
2
7
8
1
1
2
5
6
1
2
6
5
24V
+
+
10-24
3
075.1
Service Manual
Main board - Inserter power I/O (2825900V)
rev. 1.0 - 12/2009
Clutch FT2
Clutch FT1
Slotted switch FT2
RX Reading head
Slotted switch FT1
JST12
1
2
3
4
5
6
7
8
9
10
11
12
J700
FOLDERS
IN KAP
GND
VCC_OUT
GND
+5V
CO701
100nF
24V
16
15
14
13
12
11
10
R710
4K7
+3.3V
R700
4K7
+3.3V
O1
O2
O3
O4
O5
O6
O7
U502C
74LVC14
6
3.3
1
2
3
4
5
6
7
GND
C702
33pF
GND
10
U601E
74HCT14_5
5 11
D702
GREEN
FT2
R709
470R
+3.3V
D701
GREEN
FT1
R701
470R
+3.3V
U601D
74HCT14_5
8
5 9
C704
100nF
U502D
74LVC14
9 3.3 8
U700
ULN2003L
I1
I2
I3
I4
I5
I6
I7
5
C700
33pF
D700
12V
24V
GND
GND
GND
R711
1K
R702
1K
COM
GND
[2]
[2]
FV_CurveDisc_FT2
FV_RX_ReadHead [10]
FV_CurveDisc_FT1

prohibited.
[4] FV_ANA_RX_Folder
[2] FV_DIG_FCEL_FO
[4] FV_ANA_RX_Collator
[2] FV_DIG_FCEL_COLL
+5V
GND
GND
R715
1K
+5V
GND
R706
1K
+
-
+5V
R712
8K2
R704
8K2
TECHNOLOGIES BV
TEL: +31 512 589 300 / FAX: +31 512 589 399
U701B
LM358
R713
68K
U701A
LM358
R703
68K
8
rev. 1.0 - 12/2009

4
NM
TP701
FO
GND
[4] FV_TX_Folder
dist: 45mm
R717
470R
R716
150R
[4] FV_TX_ReadHead
dist: 12mm
GND
R750
1K
R707
2K2
NM
TP700
COLL
VCC_OUT
JST8
1
2
3
4
5
6
7
8
J701
TX Read head
RX Folder
TX Folder
RX Collator
Photocells
collator
side
Code:
time: 11:49:22
2825900V
Otto Tuil
Feeder Vertical FOLDER
Size
A3
Sheet 7
of 12
01
Rev:
R714
10K
C703
10nF
Drawn:
Title:
GND
GND
C701
10nF
R705
10K
Service Manual
075.1
Main board - Feeder vertical folder (2825900V)
10-25
CO804
100nF
[2] FV_MaxiFeeder_motor
[4] FV_MaxiFeeder23Detect
[2] FV_SwitchMaxiFeeder
GND
[2] FV_DIR_Collator
GND
CO805
100nF
+3.3V
U804C
74HCT14_5
5 5
6
[2] FV_PWM_Collator
[2] FV_PDisc_Collator
U804D
74HCT14_5
9 5
8
D800
BAT54S
C801
100nF
U805A
74LVC14
2 3.3 1
U804B
74HCT14_5
4
5
[2] FV_CollatorStopPosMotor
[2] FV_CollatorStopPosDir
+5V
U804A
74HCT14_5
1 5
2
GND
R815
1K
U805F
74LVC14
GND
GND
R803
10K
+5V
IN1B
IN2B
IN2A
IN1A
VBOOT
GND
Q800B
SI4946EY
R802
10K
R804
10K
C803
100nF
GND
+5V
VCP
R801
10K
+3.3V
14
15
7
6
17
C802
100nF
GND
C804
10nF
C806
100nF
R800
10K
GND
R806
100R
C800
100nF
GND
GND
C805
100nF
24V
1
2
[2] FV_ColStopPos2
6
5
+5V
GND
EN_A
Cooling plate
21
5
1
10
11
20
16
EN_B
PGND1
PGND2
PGND3
PGND4
R805
10K
24V
2
19
12
GND
13
R808
470R
+3.3V
L800
744272332
L801
744272332
U805B
74LVC14
3.3 3
3.3
10
R809
4K7
+3.3V
GND
C830
1nF
U905E
74HCT14_5
D810
STPS340U
R807
150R
TX Collator
- Collator motor
+
Pdisc collator
MF 2,3 detect
Switch MF
Motor MF
MAXI
FEEDERS
JST6
1
2
3
4
5
6
Paperstop mtr +
Paperstop mtr 1
Collator
Unit
JST10
1
2
3
4
5
6
7
8
9
10
J801
JST8
Paperstop SlottedSwitch 2
Paperstop SlottedSwitch 1
Collator
Paper-stop
Otto Tuil
Code:
time: 11:49:22
2825900V
Feeder Vertical COLLATOR
Size
A3
Sheet 8
of 12
01
Rev:
GND
Q800A
SI4946EY
GND
GND
VCC_OUT
GND
1
2
3
4
5
6
7
8
J802
J800
VCC_OUT
R830
4K7
+3.3V
Modified: Wednesday August 20 2008
Drawn:
Title:
GND
C810
10nF
24V
[4] FV_TX_Collator
R811
56R
GND
C831
1nF
1K
R832
R831
4K7
+3.3V
1K
R833
TECHNOLOGIES BV
TEL: +31 512 589 300 / FAX: +31 512 589 399
11
R810
1K
3.3
C807
33pF
GND
U805D
74LVC14
U805C
74LVC14

prohibited.
18
D801
GREEN
PD COLL.
TP800
PD COL
U800
L6205PD
SENB
SENA
OUT1B
OUT2B
OUT2A
OUT1A
VSa
VSb
[2] FV_ColStopPos1
12
13
3.3
1
2
8
7
10-26
1
075.1
Service Manual
Main board - Feeder vertical collator (2825900V)
rev. 1.0 - 12/2009
GND
JST10
1
2
3
4
5
6
7
8
9
10
J902
GND
24V
GND
CO901
100nF
+12V
GND
CO902
100nF
+12V
[2] FV_DigClutch_FE3
GND
GND
GND
C912
100nF
U905C
74HCT14_5
5 5
6
R947
39K
CO905
100nF
GND
GND
+5V
R943
5K6
R941
5K6
GND
R935
1K
R915
5K6
GND
R909
1K
GND
R914
C902
R960
1K
13
GND
C900
10nF
R906
10K
R940
C910
U905F
74HCT14_5
12
5
GND
+5V
1
2
3
4
5
6
7
GND
U901B
LM358
39K
100nF
GND
2
-
2
-
3 +
24V
GND
O1
O2
O3
O4
O5
O6
O7
16
15
14
13
12
11
10
D900
12V
GND
C904
100nF
GND
R951
4K7
R950
4K7
FV_DFC_FE2 [4]
FV_DIG_FCEL_FE2 [2]
FV_DFC_FE1 [4]
FV_DIG_FCEL_FE1 [2]
FV_Clutch_FE3
FV_Clutch_FE2
FV_Clutch_FE1
C913
100nF
TP906
DFC FE2
GND
R931
10K
GND
R948
1K
U904
ULN2003L
R944
1K
GND
R928
68K
U901A
LM358
+12V
GND
R904
10K
TP902
DFC FE1
R923
1K
U900A
LM358
R902
68K
GND
GND
R917
1K
R936
1K
I1
I2
I3
I4
I5
I6
I7
+12V
3 +
R910
1K
U900B
LM358
39K
100nF
R926
8K2
U905A
74HCT14_5
1 5
2
+5V
R900
8K2
C916
100nF
GND
C908
10nF
R929
10K
U905D
74HCT14_5
9 5
8
U905B
74HCT14_5
3 5
4
GND
R934
1K
NM
TP904
FE-2
C905
100nF
dist: 16mm
R921
39K
FV_TX_Feeder2 [4]
FV_Clutch_FE2
R916
5K6
GND
NM
TP900
FE-1
R908
1K
dist: 16mm
FV_TX_Feeder1 [4]
FV_Clutch_FE1
VCC_OUT
[4] FV_OFFSET_FE2
CO900
100nF
+12V
DFC feeder2
TX feeder-2
RX feeder-2
Clutch fe2
GND
[4] FV_OFFSET_FE1
JST10
1
2
3
4
5
6
7
8
9
10
Feeder-2
DFC feeder1
TX feeder-1
RX feeder-1
Clutch fe1
J901
VCC_OUT
8
4
8
4
ACC
R959
1K
GND
VCC
SCLin
SDAin
R919
C903
+5V
3.3
11
GND
C924
100nF
R957
10K
R958
10K
+3.3V
+5V
R922
5K6
GND
L900
L901
2K7
2K7
D902
BAT54S
R932
10K
+5V
GND
VCC_OUT
FV_Clutch_FE3
R933
10K
C922 33pF
C923 33pF
GND
GND
R956
10K
GND
R925
39K
GND
+5V
GND
C911
100nF
GND
D901
BAT54S
C907
100nF
R920
5K6
dist: 16mm
R913
1K
NM
TP901
FE-3
DFC feeder3
HCF Present
TX feeder-3
RX feeder-3
Clutch fe3
Feeder-3
JST10
1
2
3
4
5
6
7
8
9
10
J903
GND
C925
100nF
L902
2K7
JST5
1
2
3
4
5
J904
ACCESSORY
STACKER
GND
24V
Code:
time: 11:49:22
2825900V
Otto Tuil
Feeder Vertical FEEDERS
Size
A3
Sheet 9
of 12
01
Rev:
74LVC14
Drawn:
Title:
10
U502E
10nF
10nF
GND
+5V
CO906_2
GND
R912
1K
GND
R955
10K
CO906_1
SCLout
SDAout
VCC2
74LVC14
3.3
U502B
U902B
LM358
39K
100nF
R907
10K
C901
10nF
GND
R901
8K2
GND
+5V
U906
LTC4300A-2
+3.3V
+3.3V
GND
R924
1K
R918
1K
GND
R911
1K
+
-
TECHNOLOGIES BV
TEL: +31 512 589 300 / FAX: +31 512 589 399
GND
R953 10K
R954 10K
GND
+12V
R930
1K
U902A
LM358
R903
68K
TP903
DFC FE3
R905
10K
C906
100nF
GND
R952
4K7
C920 33pF
C921 33pF

prohibited.
[2] StackerPresent
[2] StackerCLK
[2] StackerSDA
[4] FV_DFC_FE3
[4] FV_OFFSET_FE3
[2] HCF_DETECT
[4] FV_TX_Feeder3
[4] FV_ANA_RX_Feeder3
[2] FV_DIG_FCEL_FE3
8
4
2
1
24V
+
+
Feeder-1
9
COM
GND
8
GND
4
2
1
rev. 1.0 - 12/2009

-
Service Manual
075.1
Main board - Feeder vertical feeders (2825900V)
10-27
MOLEX
Modular
jack
6
5
4
3
2
1
J1000
CASE
GND
+12V
R1032
1K
C1008
100nF
GND
R1004
4K7
R1000
4K7
GND
R1021
100K
R1018
100K
R1012
39K
LM358
U1003B
GND
-12V
R1001
4K7
1
U1000A
LM358
+12V
GND
C1000
1nF
-12V
C1001
1nF
-12V
Reading
Head
GND
GND
12
R1034
4K7
+5V
R1033
47K
R1006
47K
GND
CO1003
100nF
GND
CO1002
100nF
CO1004
100nF
GND
+5V
U1004C
HC4066
R1013
680K
-12V
R1007
100K
GND
GND
GND
+3.3V
U1004D
HC4066
CO1001
100nF
GND
+5V
GND
C1009
100nF
GND
R1005
4K7
+2.5V
D1000
BAT54S
U1000B
LM358
R1025
10K
GND
C1004
1nF
5 +
C1002
10nF
CO1000_2
100nF
-12V
R1024
10K
R1023
82R
C1005
1nF
+12V
R1022
56R
C1003
10nF
R1003
6k8
R1019
10K
CO1000_1
100nF
+5V
R1002
6K8
2
1
+5V
2
-
3 +
R1020
47K
R1011
100K
GND
U1004A
HC4066
R1014
680K
5 +
7
GND
TP1000
OMR_OUT
Rv=27K
R1017
47K
GND
R1026
8K2
+5V
GND
BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7
3 +
[2,3,11,12]
[3,12]
[2,3,11,12]
Otto Tuil
Code:
time: 11:49:22
2825900V
Feeder Vertical READING
Size
A3
Sheet 10 of 12
01
Rev:
FV_ANA_RX_ReadHead [4]
FV_DIG_FCEL_RH [2]
FV_ReadHead_S3 [2]
FV_ReadHead_S2 [2]
FV_ReadHead_DAC0 [12]
FV_ReadHead_S0 [2]
FV_ReadHead_S1 [2]
RH_ADC_START [2]
nRD
nCS3
BD[0..15]
U1003A
LM358
R1027
68K
R1040
10K
GND
R1031
1K
GND
+5V
U1002
AD7819
6
5
8
9
10
11
12
13
14
15
Drawn:
GND
C1010
10nF
R1028
10K
RD
CS
DB0
DB1
DB2
DB3
DB4
DB5
DB6
DB7
CONVST
GND
BUSY
Vref
Vin
+3.3V
Andromeda DS-70 mainboard
R1030
150R
R1029
150R
dist: 12mm
Title:
GND
TP1001
ReadHead
C1006
100nF
C1007
100nF
AVREF
2,5 Volt
GND
R1010
1K
GND
[7] FV_RX_ReadHead
GND
R1016
68K
R1008
470R
Fast readhead ADC
TECHNOLOGIES BV
TEL: +31 512 589 300 / FAX: +31 512 589 399
U1004B
13 HC4066
R1015
47K
R1009
100K
U1001B
LM358

prohibited.
U1001A
LM358
GND
10
11
2
1
9
8
3
4
16
VDD
GND
3
10-28
4
075.1
Service Manual
Main board - Feeder vertical reading (2825900V)
rev. 1.0 - 12/2009
GND
CO1102
100nF
+5V
HORUS
CONNECTION
JST12
1
2
3
4
5
6
7
8
9
10
11
12
J1102
CO1104
100nF
RXD2
TXD2
1
2
3
J1120
JST5
1
2
3
4
5
CON3
+3.3V
RXD1
TXD1
+24V
+5 Volt
DataData+
GND
SHIELD
J1100
GND
GND
CO1100_1
100nF
+5V
GND
GND
56R
56R
56R
56R
CO1100_2
100nF
R1123
R1121
R1122
R1120
+5V
[2] USB_HOST_CON
C1120
10nF
GND
+3.3V
GND
24V_IN
CASE
GND
GND
C1106
33pF
R1109
10K
GND
GND
C1105
33pF
NM
R1102
R1100
R1104
R1103
GND
C1130
10nF
+5V
T2OUT
R2IN
T1OUT
R1IN
GND
1
2
3
4
R1111
2K2
EECS
EESK
EEDATA
C1122
10nF
GND
GND
GND
33pF
C1108
GND
GND
CO1100_3
100nF
+3.3V
100nF
100nF
100nF
CO1101
100nF
C1112
100nF
1 C1109
3
4 C1110
5
2 C1111
6
10
9
11
12
U1104
MAX232ACSE
C+
C1C2+
C2V+
V-
T2IN
R2OUT
T1IN
R1OUT
+5V
47
48
44
43
8
7
CO1103
100nF
GND
+5V
GND
R1141
NM
10K
R1140
NM
10K
R1112
10K
R1125
10K
TEST
EEDATA
EESK
EECS
RESET
XTOUT
XTIN
RSTOUT
USB DM (-)
USB DP (+)
GND
R1113
4K7
100nF
C1101
R1101
470R
+3.3V
[2]
[2]
[2]
[2]
26
41
30
29
28
27
40
39
38
37
36
35
33
32
21
19
16
17
20
22
24
23
10
15
13
12
11
GND
R1131
4K7
+3.3V
R1127
1K
B1
B2
B3
B4
B5
B6
B7
B8
GND
1
19
2
3
4
5
6
7
8
9
BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7
nCS1
U1101B
74LVC32
GND
R1115
10K
GND
R1116
10K
GND
TECHNOLOGIES BV
TEL: +31 512 589 300 / FAX: +31 512 589 399
R1114
10K
[2,3,12]
[3]
GND
11
R1128
1K
U1101C
74LVC32
12
U1101D
74LVC32
Otto Tuil
CPU USB I/O

Code:
time: 11:49:22
2825900V
Size
A3
Sheet 11 of 12
01
Rev:
BOARD_ID[0..3]
[3]
[2,3,10,12]
Drawn:
Title:
R1117
10K
BOARD_ID0
BOARD_ID1
BOARD_ID2
BOARD_ID3
nWR
nCS1
nRD
[2,3,10,12]
[3]
[2,3,10,12]
USB_RXF# [2]
USB_TXE# [2]
nRD
nCS1
BD[0..15]
ARM_POWER_ON_RESET [2]
[2]
[2]
ARM_BOOT_MODE [2]
RXD1
TXD1
R1151
4K7
+3.3V
U1101A
74LVC32
R1150
4K7
+3.3V
U1103
74LVC245
DIR
OE
A1
A2
A3
A4
A5
A6
A7
A8
U805E
74LVC14
10 3.3 11
18
17
16
15
14
13
12
11
R1152
4K7
+3.3V
+3.3V
BOARD_ID[0..3]
R1126
1K
R1133
4K7
+3.3V
HARDWARE IDENTIFICATION
+3.3V
BOARD_ID0
BOARD_ID1
BOARD_ID2
BOARD_ID3

prohibited.
TXD2
RXD2
TXD1
RXD1
U1100
FT2232
SI/WUB
PWREN
RXF#
TXE#
RD
WR
FIFO D0
FIFO D1
FIFO D2
FIFO D3
FIFO D4
FIFO D5
FIFO D6
FIFO D7
CTS
DSR
RI
DCD
DTR
RTS
TXD
RXD
SI/WUA
TXDEN
SLEEP
RXLED
TXLED
+3.3V
13
USB Connectivity
3V3OUT
GND
R1124
4K7
GND
33pF
X1100
6,0MHz
C1107
R1130
470R
C1132
10nF
GND
R1105
1K
56R
56R
56R
56R
C1131
10nF
RS232 driver
CS
SK
DIN
DOUT
R1110
10K
93C46
VCC
NC
NC
GND
U1102
CO1100_4
100nF
7
8
14
13
8
7
6
5
CONFIG EEPROM
R1108
4K7
C1121
33pF
46
AVCC
AGND
USB
Device
16
VCC
GND
15
3
42
VCC
VCC
45
1
2
14
31
VCCIOA
VCCIOB
GND
GND
GND
GND
9
18
25
34
20
VCC
GND
10
rev. 1.0 - 12/2009

10
Service Manual
075.1
Main board - CPU USB I/O (2825900V)
10-29
LCD_CL1
LCD_CL2
LCD_DD0
LCD_DD1
LCD_DD2
LCD_DD3
LCD_FRM
LCD_ENABLE
A0
A1
nCS3
nWR
[3]
[2,3]
[3,10]
[2,3,11]
[2,3,10,11] BD[0..15]
[2] SPI_MPLEX_CS2
[2,4] SPI1_ADC_DAT
[2] SPI_MPLEX_CS1
[2,4] SPI1_CLK
[2,4] SPI1_DAC_DAT
[3]
[3]
[3]
[3]
[3]
[3]
[3]
[2]
CO1200
100nF
10
+3.3V
R1234
470R
GND
1
19
2
3
4
5
6
7
8
9
CO1201
100nF
U305C
74LVC32
14
13
12
11
10
9
8
7
17
16
WR
DB0
DB1
DB2
DB3
DB4
DB5
DB6
DB7
A0
A1
GND
GND
18
17
16
15
14
13
12
11
Vref
19
20
CO1204_1
100nF
U1202
MAX5100
OUT D
OUT C
OUT B
OUT A
+5V
L1209
L1208
L1226
L1210
J1200
GND
CO1203_2
100nF
+5V
GND
C1207
1nF
GND
+3.3V
CO1204_2
100nF
GND
C1208
33pF
AUDIO_TRACK
L1225
2K7
CO1202
100nF
GND
L1222
2K7
CONTRAST
2K7
L1260
C1260
33pF
VCC_OUT
1
3
5
7
9
11
13
15
17
19
MicroMatch20
2
4
6
8
10
12
14
16
18
20
CO1205_2
100nF
GND
1
3
5
7
9
11
13
15
17
19
21
23
25
R1217
R1219
R1218
C/D DISP.
READ DISP.
100R
100R
100R
100R
100R
100R

prohibited.
GND
CONBOX26
VCC_OUT
J1201
2
4
6
8
10
CE DISP. 12
WRITE DISP.
14
RESET DISP.
16
18
20
22
24
26
R1213
R1216
R1215
SI62 LCD connection
COLOR LCD connection
R1244
100R
R1241
100R
C1200
100nF
100R
2K7
2K7
2K7
2K7
2K7
2K7
2K7
2K7
2K7
2K7
2K7
2K7
L1202
L1206
L1203
L1207
L1200
L1201
L1204
L1205
R1260
GND
CO1205_1
100nF
GND
R1239
39K
R1237
10K
U601C
74HCT14_5
6
5
100R
100R
100R
100R
100R
100R
100R
100R
100R
100R
100R
100R
R1209
R1205
R1212
R1222
R1200
R1201
R1202
R1208
R1223
R1224
R1250
R1225
D1200
BAT54S
U1201
74LVC245
B1
B2
B3
B4
B5
B6
B7
B8
18
17
16
15
14
13
12
11
U1200
74LVC245
B1
B2
B3
B4
B5
B6
B7
B8
+5V
GND
DIR
OE
A1
A2
A3
A4
A5
A6
A7
A8
+3.3V
GND
CO1203_1
100nF
+3.3V
8 6
BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7
FAST DAC
GND
GND
R1214
470R
R1233
10K
DIR
OE
1
19
A1
A2
A3
A4
A5
A6
A7
A8
+3.3V
2
3
4
5
6
7
8
9
+3.3V
20
VCC
GND
10
VCC
GND
20
LDAC
C1202
2K7
2K7
C1210
1nF
R1236
GND
+5V
R1270
1K
21
20
19
18
17
16
15
14
21
20
19
18
17
16
15
14
R1221
470R
U601F
74HCT14_5
12
5 13
GND
R1220
470R
21
20
19
18
17
16
15
14
B1
B2
B3
B4
B5
B6
B7
B8
A1
A2
A3
A4
A5
A6
A7
A8
B1
B2
B3
B4
B5
B6
B7
B8
A1
A2
A3
A4
A5
A6
A7
A8
+5V +3.3V
GND
B1
B2
B3
B4
B5
B6
B7
B8
GND
2
22
3
4
5
6
7
8
9
10
R1265
1K
A1
A2
A3
A4
A5
A6
A7
A8
+3.3V
nRD
4
nRD
Otto Tuil
Code:
USER INTERFACE
[3]
[2,3,10,11]
LCD_RESET [2]
SI62_LCD_OE [2]
nCS4
[2,3,10,11]
[3]
[2,3,10,11]
[2,3,10,11]
SI62_LCD_OE [2]
time: 11:49:22
2825900V
A3
Sheet 12 of 12
Size
01
Rev:
[2,3,10,11]
[2,3,11]
nRD
nWR
2
22
GND
[3]
SI62_LCD_CD [2]
nCS4
R1245
470R
U305D
74LVC32
13
12
BD[0..15]
nCS5
U305B
74LVC32
GND
BD[0..15]
3
4
5
6
7
8
9
10
U1205
74LVX3245
DIR
OE
BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7
11
U1204
74LVX3245
DIR
OE
+5V +3.3V
GND
2
22
BD0
BD1
BD2
BD3
BD4
BD5
BD6
BD7
U1203
6
74LVX3245
DIR
OE
3
4
5
6
7
8
9
10
Andromeda DS-70 mainboard
100R
100R
100R
100R
100R
100R
100R
100R
100R
100R
100R
100R
100R
GND
33pF
C1206
R1204
10K
+5V +3.3V
Drawn:
Title:
R1243
R1242
R1240
R1238
GND
TECHNOLOGIES BV
TEL: +31 512 589 300 / FAX: +31 512 589 399
2K7
2K7
L1221
L1224
L1223
2K7
L1220
L1219
GND
33pF
C1205
R1230
R1227
R1226
R1232
R1231
R1229
R1228
R1235
33pF
C1204
GND
2K7
2K7
2K7
2K7
2K7
2K7
2K7
2K7
33pF
C1203
GND
L1215
L1211
L1216
L1212
L1217
L1213
L1218
L1214
GND
33pF
GND
33pF
C1201
R1211
10K
+5V
SI62 keyboard readout

+5V
R1207
10K
+5V
R1210
10K
+5V
R1206
10K
+5V
R1203
10K
+5V
24
VCCB
10
SHDN
15
VDD
GND
18
24
VCCB
1
VCCA
GND
GND
GND
13
12
11
24
VCCB
1
VCCA
GND
GND
GND
13
12
11
1
VCCA
GND
GND
GND
10-30
13
12
11
075.1
Service Manual
Main board - User interface (2825900V)
rev. 1.0 - 12/2009
Service Manual
075.1
GND
U100
DS2431P
NC
NC
NC
DATA
GND
GND
JST2
1
2
J100
3
4
5
ID-Tag (2994504Z)
rev. 1.0 - 12/2009
10-31
075.1
10.3
Service Manual
Product coding for CRM
10.3.1 Failure symptoms

Code
Failure symptoms
SD550
Unable to run mail
SD560
Document jam
SD570
Unable to connect to OLS
SD580
Document feeding issue
SD810
Envelope feeding issue
SD820
Envelope jam
SD830
Display operation issue
SD840
Noisy machine
SD850
No power
SD860
Envelope sealing issue
SD990
Symptom not coded
10.3.2 Module
Code
Module
D042
Document Feeder
D081
Collator
D167
Document Folder
D244
Envelope Feeder
D281
Empty Envelope Transport
D364
Document Insertion Area
D401
Envelope Ejection Area
D444
Envelope Sealing and Exit Area
D511
Main Drive
D551
Miscellaneous Area
D707
Vertical stacker
D820
Server
D831
Customer environment / operation
D840
OpCo / Service operation
D890
Origin not found
D990
Module not coded
10-32
rev. 1.0 - 12/2009
Service Manual
075.1
10.3.3 Failure origins

Code
Module
Failure origin
D032250
Document Feeder
Photocell
D042250
Document Feeder
Photocell
D042260
Document Feeder
DFC Thickness detector
D042270
Document Feeder
Wiring
D042450
Document Feeder
Paper pull roller
D042460
Document Feeder
Separation roller
D042470
Document Feeder
Transport rollers
D042490
Document Feeder
Axle
D042510
Document Feeder
Clutch
D042530
Document Feeder
Belt
D042540
Document Feeder
Belt tensioner
D042550
Document Feeder
Pressure spring
D042580
Document Feeder
OMR paper guides
D042590
Document Feeder
OMR reading head
D042600
Document Feeder
Lever high capacity feeder
D042990
Document Feeder
Origin not coded
D081250
Collator
Photocell
D081260
Collator
Motor
D081270
Collator
Switch
D081280
Collator
Wiring
D081450
Collator
Collator roller
D081460
Collator
Bearing
D081470
Collator
Axle
D081490
Collator
Pulley
D081500
Collator
Timing belt
D081510
Collator
Collator belt
D081550
Collator
Pulse disc
D081560
Collator
Stop positioner
D081990
Collator
Origin not coded
D167250
Document Folder
Photocell
D167260
Document Folder
Wiring
D167450
Document Folder
Fold roller
rev. 1.0 - 12/2009
10-33
075.1
Service Manual
Code
Module
Failure origin
D167460
Document Folder
Bearing
D167470
Document Folder
Axle
D167480
Document Folder
Gear
D167490
Document Folder
Clutch
D167500
Document Folder
Pulley
D167510
Document Folder
Belt
D167540
Document Folder
Folding knife
D167570
Document Folder
Cam disc
D167620
Document Folder
Brake disc
D167990
Document Folder
Origin not coded
D244250
Envelope Feeder
Wiring
D244450
Envelope Feeder
Feed roller
D244460
Envelope Feeder
Jogger roller
D244470
Envelope Feeder
Separation roller
D244480
Envelope Feeder
Bearing
D244490
Envelope Feeder
Axle
D244500
Envelope Feeder
Gear
D244510
Envelope Feeder
Clutch
D244520
Envelope Feeder
Pulley
D244530
Envelope Feeder
Belt
D244550
Envelope Feeder
Hopper side guide
D244560
Envelope Feeder
Semi automatic envelope separation
D244990
Envelope Feeder
Origin not coded
D281250
Photocell
D281260
Wiring
D281450
Transport roller
D281460
Track roller
D281470
Flap roller
D281480
Bearing
D281490
Axle
D281500
Gear
D281510
Clutch
D281520
Pulley
10-34
rev. 1.0 - 12/2009
Service Manual
Code
Module
Failure origin
D281530
Belt
D281550
Flap scraper
D281560
Friction brake
D281990
Origin not coded
D364250
Photocell
D364260
Finger solenoid
D364270
Wiring
D364450
Insert roller
D364460
Bearing
D364470
Axle
D364480
Gear
D364490
Clutch
D364500
Pulley
D364510
Belt
D364520
Leaf spring
D364540
Fingers
D364990
Origin not coded
D401250
Ejection solenoid
D401260
Photocell
D401270
Wiring
D401450
Ejection roller
D401460
Bearing
D401470
Axle
D401480
Gear
D401490
Pulley
D401500
Belt
D401520
Spring
D401990
Origin not coded
D444250
Solenoid
D444260
Photocell
D444270
Water level detection
D444280
Wiring
D444450
075.1
Envelope reverse roller
rev. 1.0 - 12/2009
10-35
075.1
Service Manual
Code
Module
Failure origin
D444460
Envelope sealing roller
D444470
Bearing
D444480
Axle
D444490
Gear
D444500
Pulley
D444510
Belt
D444540
Moistening cloth
D444560
Brush holder
D444990
Origin not coded
D511250
Main Drive
Main motor
D511260
Main Drive
Photocell
D511270
Main Drive
Wiring
D511450
Main Drive
Bearing
D511460
Main Drive
Axle
D511470
Main Drive
Gear
D511480
Main Drive
Clutch
D511490
Main Drive
Pulley
D511500
Main Drive
Belt
D511520
Main Drive
Pulse disc
D511990
Main Drive
Origin not coded
D551020
Miscellaneous Area
Main Board
D551030
Miscellaneous Area
Communication board
D551040
Miscellaneous Area
Connection board
D551050
Miscellaneous Area
Display Board
D551060
Miscellaneous Area
ID tag
D551125
Miscellaneous Area
Software
D551250
Miscellaneous Area
Power supply
D551260
Miscellaneous Area
Dongle
D551270
Miscellaneous Area
Fuse
D551280
Miscellaneous Area
Power switch
D551290
Miscellaneous Area
Cover switch
D551300
Miscellaneous Area
Power cable
D551450
Miscellaneous Area
Cover
10-36
rev. 1.0 - 12/2009
Service Manual
075.1
Code
Module
Failure origin
D551750
Miscellaneous Area
Display assembly
D551990
Miscellaneous Area
Origin not coded
D707250
Vertical stacker
Main board
D707260
Vertical stacker
Clutch
D707270
Vertical stacker
Wiring
D707280
Vertical stacker
Photocell
D707290
Vertical stacker
Switch
D707450
Vertical stacker
Cover
D707460
Vertical stacker
Transport roller
D707470
Vertical stacker
Axle
D707480
Vertical stacker
Gear
D707490
Vertical stacker
Side guide
D707750
Vertical stacker
Gear box
D707760
Vertical stacker
Stack mechanism
D707770
Vertical stacker
Top load assembly
D707990
Vertical stacker
Origin not coded
D820125
Server
OLS server not available
D820990
Server
Origin not coded
D831250
Phone adaptor
D831260
Phone line filter
D831270
Phone cable
D831920
User setting
D831925
Supervisor setting
D831930
PABX setting
D831935
No phone line
D831940
Phone line too far
D831945
Several devices on phone socket
D831950
Envelope not appropriate
D831955
Document not appropriate
D831960
Incorrect user operation
D831990
Origin not coded
D840915
ERP(SAP) incorrect operation
D840920
Service settings
rev. 1.0 - 12/2009
10-37
075.1
Service Manual
Code
Module
Failure origin
D840930
Incorrect Service operation
D840990
Origin not coded
D890990
Origin Not Found
Origin not found
D990990
Module Not Coded
Origin not coded
10-38
rev. 1.0 - 12/2009
Service Manual
10.4
075.1
Checklist training operator
Check
Subject
Introduction
-
Explain machine function
Operator manual: read it!
Safety
-
Keep long hair, jewellery, fingers away from rotating parts
Power: earthing, local mains voltage
Explain process flow

Starting up
-
Install document feeder trays
Install slide and envelop catch tray
Connect to mains, power on
Loading documents: document orientation, side guides,

separation
Loading envelopes: side guides, stacker side guides,

separation
Sealing: fill water reservoir
Automatic
-
Explain Automatic
Select a job
-
Job info, explain all icons
Test run
Counters
Explain buttons on control panel

Daily mail
Create a new job
Job wizard
Job settings
-
Document settings
Fold settings
rev. 1.0 - 12/2009
Envelope settings
Double Feed Control settings
10-39
075.1
Check
Service Manual
Subject
-
Job name
Display settings
Supervisor Menu
-
System info
Options information and system information
Test menu
Job menu
Edit a job
Copy a job
-
Save an Automatic job
Delete a job
Fault finding
-
Error messages
Special errors (technical errors)
Warning screen (cover open)
Last error screen, supervisor menu
Clearing stoppages
-
Show all areas
How to remove jams
Operator troubleshooting
-
Adjust insert position, explain when and how
Adjust insert fingers, explain when and how
Adjust address position
Maintenance, daily
-
Clean exterior
Clean sealing table and rollers
Maintenance, weekly
-
Replace brushes
Replace moistening cloth
Maintenance when necessary: clean sensors

Options
10-40
rev. 1.0 - 12/2009
Service Manual
Check
075.1
Subject
-
Activate an option
Reading
-
Explain functioning of reading (codes and marks)
Document orientation
Reading settings in Job menu
Reading Test menus
Adjust reading head position
Reading errors
Mailing / Franking options

-
Mailing / Franking settings in Job menu
Online services
-
Connection status
Manual connection
New messages (install new config / job)
Messages
Configuration (modem volume)
MPPC
-
MPPC settings in Job menu
MaxiFeeder
-
Adjust side guides
Document separation
Feeding documents
High Capacity Feeder

-
Installation of feeder tray
Adjust side guides
Document separation
Feeding documents

-
Installation
Adjust side guides
Side exit
rev. 1.0 - 12/2009
10-41
075.1
Check
Service Manual
Subject
Envelope / paper characteristics:
-
Window quality
Glue
Internal/external glueing
10-42
Storage (humidity and temperature)
Fingers
rev. 1.0 - 12/2009
Service Manual
10.5
075.1
10.5.1 Process description
CL1
The processing of envelopes or document sets is as follows:

1
2
3
4
The exit photocell of the inserter system (PH4) sees the envelope or document set. This
activates clutch CL1 of the vertical stacker.
The rollers 1 to 6 transport the envelope into the stacker.
The envelope lands on a shovel and the stacker photocell PH1 detects the end of the
envelope.
The shovel lifts the envelope, the fingers pick up the envelope and stack it. A slotted
photocell monitors this stacker cycle.
rev. 1.0 - 12/2009
10-43
075.1
Service Manual
10.5.2 (Dis)assembly - High Capacity Vertical Stacker
Note: Handle the high capacity vertical stacker with care. Never disassemble the stack
mechanism.
Remove covers
1
Top cover assy (4)

To remove the top cover assy:
1
2
3
Remove the guard plate (5).

Remove the six torx screws that hold the cover plate.
Remove the top cover assy.
Bottom plate (2)

1
2
3
Place the machine carefully at the back side on a felt path.

Remove the six screws that hold the bottom plate.
Side cover LH (1)

1
2
3
Remove the screw from the bottom plate (2) that holds the side cover.
Remove the screw from the top cover assy (4) that holds the side cover.
Remove the third screw that holds the side cover.
10-44
rev. 1.0 - 12/2009
Service Manual
075.1
Turn the cover and remove it.
Side cover RH (3)

1
2
3
4
Remove the screw from the bottom plate (2) that holds the side cover.
Remove the screw from the top cover assy (4) that holds the side cover.
Remove the third screw that holds the side cover.
Turn the cover and remove it.
Stack mechanism
1
In case the stack mechanism is defective, the complete unit has to be replaced.
To replace the stack mechanism:
1
2
3
4
5
6
7
8
Remove the top cover assy ( Remove covers on page 10-44).

Remove the side covers.
Disconnect the wire at the pulse disc sensor in the stack mechanism (5).
Remove the gear 29T from the RH side (7).
Remove the screw that holds the support plate RH (6) and remove the plate.
Remove the screw that holds the support plate LH (2) and remove the plate.
Slide complete stacker mechanism (4) from the back plate.
Note: On replacement make sure that both stack units are synchronized. See
Synchronizing stacker mechanism on page 10-54.
rev. 1.0 - 12/2009
10-45
075.1
Service Manual
Back guide
Remove the back guide assy

1
2
3
4
Remove the guard plate.

Disconnect the connector (2) of the back guide.
Press the leaf springs (1) that hold the guide axles to the inside direction.
Pull the back guide (3) out of the stacker.
When you reinstall the back guide: push the pins through the holes on both sides until you hear
a click on both sides. If you do not hear a click, the thick part of the guide axle did not pass the
leaf spring completely. In that case use a screw driver to enforce the leaf spring.
10-46
rev. 1.0 - 12/2009
Service Manual
075.1
Remove the pressure arm
1
2
3
4
5
6
7
8
Remove the two torx screws that hold the back guide cover (1).
Slide the back guide cover down and lift it from the back guide assy.
Remove the cable guide plate (2) at the bottom.
Remove the nuts that secure the guide rail (3).
Slide the guide rail from the pressure arm (4).
At the front side unscrew the weights (5).
Remove both rollers, plastic rings and screw.
Remove the pressure arm (4).
Note: On replacement take care of the wiring.
rev. 1.0 - 12/2009
10-47
075.1
Service Manual
PCB
1
2
3
4
Remove the RH cover ( Remove covers on page 10-44).

Disconnect all connectors from the PCB.
Remove the nut and both washers (2) that hold the PCB (1).
Remove the PCB carefully.
Leaf spring assy
1
2
3
Remove the guard plate.

Remove the two screws (1) that hold the leaf spring assy (2).
Remove the leaf spring assy.
10-48
rev. 1.0 - 12/2009
Service Manual
075.1
Gear box assy
1
2
3
4
Remove the two torx screws (1) and screw (2) that hold the envelope transportation
table (3).
Remove the envelope transportation table.
Open the pinch (4).
Lift the safety plate and remove the gear box assy (5) from the axle.
rev. 1.0 - 12/2009
10-49
075.1
Service Manual
Transportation rollers
1
Remove the both side covers, the top cover assy and the envelope transportation table.
Rollers on axle (1)

1
2
3
4
Remove spring clip, washer and bearing from the RH side of axle (1).
Slide the axle to the left.
Remove gear 18T from the axle. Take care of the cyl. pin.
Remove the rollers (2) from the axle. Take care of the cyl. pins.
Axle assy (3)

1
2
3
4
5
Remove the clutch (7), spacer, washer and bearing from the RH side of axle (3) (see
Clutch on page 10-50).
Remove the spring clip, washer and bearing from the LH side of axle (3).
Slide the axle to the left.
Remove gear 18T from the axle. Take care of the cyl. pin.
Slide the axle to the right and remove it.
Clutch
1
2
3
4
5
Remove the RH side cover and top cover assy.

Remove the support RH (6).
Remove the two screws that hold the connection pivot (8) and remove the pivot.
Remove the spring clip, washer, gear 20T (4), slip clutch (5) and coupling plate from the
axle.
Disconnect the clutch (7) and remove it from the axle.
10-50
rev. 1.0 - 12/2009
Service Manual
075.1
(Dis)assembly sensors
Microswitch in back guide
1
2
3
4
Remove the back guide from the stacker.

Remove the two torx screws that hold the back guide cover (see Remove the pressure
arm on page 10-47).
Slide the back guide cover down and lift it from the back guide assy.
Remove the nut that holds the microswitch.
Safety switch
1
2
Remove the top cover assy and the RH side cover.

Remove the safety switch.
rev. 1.0 - 12/2009
10-51
075.1
Service Manual
Photocell transmitter (LED)
1
2
Lift the safety plate (2) to get access to the screw (1) that holds the transmitter (3).
Remove the transmitter.
10-52
rev. 1.0 - 12/2009
Service Manual
075.1
Photocell receiver (sensor)
1
2
3
4
5
Remove the back guide.

Remove the envelope transportation table (1).
Remove the photocell transmitter to get access to the photocell receiver (2).
Put a screw driver through the hole of the transmitter and remove the screw that holds the
receiver.
Remove the receiver.
rev. 1.0 - 12/2009
10-53
075.1
Service Manual
10.5.3 Preventive maintenance

Average preventive service visits should take place at approximately 160.000 inserts (see
service menu, service counters). The table below shows the intervals.
Please note that there is a statistical relationship between the actual average monthly volume
and the service requirements of the machine. Significant larger average volumes might double
the yearly service requirements.
Maintenance
Number of cycles
Service visit
+/- 160.000
160k
+/- 330.000
160k
+/- 500.000
500k
+/- 660.000
160k
+/- 830.000
160k
+/- 1.000.000
500k
10
+/- 1.660.000
160k
11
+/- 1.800.000
160k
....
....
Note
It is recommended to service the machine at least twice a year.
160K service visit
Clean photocells.
Clean the transportation area / transportation rollers.
Check the adjustment of the side guides.

500K service visit
Perform 160K activities
Replace transportation rollers (see Drive on page 10-60, item 29) and drive axle assy
(item 1) if necessary.
Replace the gear box assy (see Drive on page 10-60, item 2) and the leaf spring assy
(item 6) if necessary.
10.5.4 Troubleshooting
Synchronizing stacker mechanism
If both stacker units are not running synchronic, synchronize them as follows:
1
2
3
Remove the RH side cover.

Make sure that the leaf spring rests in the notch of the curved gear. If not, turn the upper
axle in the stacker unit until you hear a click.
Repeat this for the left hand side.
10-54
rev. 1.0 - 12/2009
+5V
VCC
LM393
LM393
VEE
11
GND
CO102
100nF
H100
4.3mm
74HCT14
IC100E
10
GND
+5V
GND
CO100
100nF
22R
R122
R121
22R
D100
BAT54S
+5V
GND
R109 +5V
10k
74HCT14
14
IC102C
VCC 8
74HCT14
GND
IC100F
12
IC102B
13
R108
10k
JST7
1
2
3
4
5
6
7
J100
IC100G
+5V
SDA
SCL
StackerPresent
GND
+24V
StackerClutch
+5V
Accessory connector
+5V
H101
4.3mm
GND
H102
4.3mm
74HCT14
IC100D
8
GND
GND
GND
D101
BAT54S
1
2
3
13
15
14
A0
A1
A2
INT
SDA
SCL
IC101
+5V
16
VCC
GND
rev. 1.0 - 12/2009

PCF8574T
P0
P1
P2
P3
P4
P5
P6
P7
4
5
6
7
9
10
11
12
CO101
100nF
GND
GND
+5V
+5V
R105
1k
C101
100nF
GND
C100
100nF
R115
10k
GND
+5V
IC100C
6
5
LM393
GND
C103
100nF
GND
R116
10k
R123
1k
R124
10k
C102
100nF
R107
10k
R104
10k
R102
10k
GND
+5V
GND
IC102A
220k
R114
10k R113
10k
R118
74HCT14
R117
4.7k
74HCT14
IC100A
2
1
74HCT14
IC100B
3
4
R103
1k
+5V
D103
40V 1A
D102
12V
COVER
GND
GND
R112
15k
1
2
3
4
5
6
7
8
9
1 +24V
2 NC
3 Interlock Cover
+5V
One turn photoswitch
GND
Stacker Full microswitch
GND
+5V
Start Stacker Rx
+5V
Start Stacker Tx
JST2
1
2
J102
1 +24V
2 StackerClutch
Clutch
JST3
1
2
3
J103
Cover
R111
220R
JST9
1
2
3
4
5
6
7
8
9
J101
Inputs
GND
GND
+5V
Service Manual
075.1
10.5.5 Electrical diagram HCVS-1 (2825913J)
10-55
075.1
Service Manual
10.5.6 Parts list

Covers
10-56
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
*
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Bottom plate
Side guide RH
Side guide LH
Side guide kit (both LH and RH)
Magnetic clip
Wedge
Guard plate (top)
Guard plate (top)
Screw 5.0x14
Torx screw m4x8
MPPC camera V2
Cover RH
Top cover assy.
Stacker cover RH
Cover LH
Stacker cover LH
Decorative cover
Finger knob assy.
Mounting bracket
2825692D
2825696H
2825697J
2825828V
2957090B
2825725N
2825613W
2825809A
2053621N
2989183G
2053850B
2454302P
2818114K
2825709W
2825796M
2825883C
2825712Z
2825705S
2825714B
2825667C
2825711Y
1
1
1
2
2
1
1
7
10
8
2
1
1
1
1
1
1
1
1
1
Remarks
*
*
See note
See note
See note
Optional
See note
See note
Note
In case the optional MPPC is mounted.
rev. 1.0 - 12/2009
10-57
075.1
Service Manual
Frame parts etc.
10-58
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
12
13
13
14
15
16
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Connection cable (external)

Tension spring
Not used
Mounting clamp
Torx screw M4x8
Back plate
Spacer 8x4,3x10mm
Strain relief
Bottom frame assy.
Support RH
Support LH
Connection frame LH
Cross bar
Connection pivot (left)
Spring clip 6-8mm
Connection pivot (right)
Envelope transportation table
Bracket
Connector 3p (JST)
Safety plate (assy)
Grommet
Retaining leaf spring
Torx screw m4x8
Microswitch (including lever)
PCB
Nut m4
Wire saddle
Print-board holder
Nut m3 (self-locking)
Paint piercing washer 8x4,3x0,5
Connection frame RH
2825932D
2825890K
1
2
2121489J
2825892M
2042453E
2825611U
2046919G
2825602K
2825813E
2825748M
2825745J
2825621E
2825765E
2454314B
2825614X
2052446P
2825617A
2825612V
2825622F
2969833A
2825721J
2120851U
2825616Z
2053850B
2989056Z
2825913J
2451902P
2814768Z
2041075U
2453853W
2053628V
2453702P
2052431Y
2042452D
2825628M
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
4
2
16
1
1
1
2
2
2
1
1
1
1
1
rev. 1.0 - 12/2009
Remarks
10-59
075.1
Service Manual
Drive
10-60
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Drive axle assy.

Gear box assy.
Screw 5.0x14
Clutch ccw 8mm
Spacer 12x8,3x3mm
Leaf spring assy.
Torx screw M4x8
Gear 21T
Gear 29T
Cyl. pin 2,5x24mm
Coupling plate
Drive axle
Gear 18t
Slip clutch
Spring clip 9-12mm
Washer 14x8,2x0,8mm
Cyl. pin 2,5x16
Bearing 10mm
Gear 20t
Bearing 6mm
Spring clip 6-8mm
Transportation axle
Spring clip 7-9mm
Gear 32T assy.
Gear 30T assy.
Pressure spring
Washer 12x6,2x0,8mm
2825849S
2825826T
2989183G
2930536R
2041050T
2825827U
2825892M
2825751Q
2825752R
2052349N
2958056H
2825647G
2957376Z
2947396D
2052455Y
2040141W
2052346K
2042426B
2040143Y
2964199G
2042424Z
2042851U
2052446P
2825641A
2052442K
2825653N
2825655Q
2033520Z
2042976Z
2040140V
rev. 1.0 - 12/2009
Remarks
1
1
1
1
1
1
2
1
1
1
1
1
2
1
4
1
4
4
4
1
4
4
5
2
3
1
1
4
2
4
10-61
075.1
Service Manual
Backguide
10-62
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Retaining plate
Sealing plug
Roller 30mm
Cable guide
Microswitch
Guide rail
Pressure arm
Guide axle
Weight (for stacker)
Set screw m5x25
Torx screw m4x8
Grommet
Nut m3 (self-locking)
Mounting plate
Backguide cover
Backguide frame
2825837E
2040905S
2969579L
2825810B
2825265J
2825772M
2825785A
2825632R
2969580M
2082849J
2040143Y
2053850B
2120851U
2053621N
2053628V
2825811C
2825719G
2825759Y
rev. 1.0 - 12/2009
Remarks
1
2
2
1
1
1
1
2
2
1
2
3
2
6
1
1
1
1
10-63
075.1
Service Manual
Stack mechanism
10-64
rev. 1.0 - 12/2009
Service Manual
075.1
Number
Description
1
2
3

Stack mechanism unit complete
Screw 5.0x14
2975505J
2825432Z
2989183G
Remarks
1
1
4
10.5.7 Recommended spare parts HCVS-1
Page ref.
Legend
no.
Description
Part No
Stock per
number of
installed
machines
1
10
Remarks
50
page 10-56
2&3
Side guides
2825696H
& 2825697J
page 10-58
26
Micro switch
2989056Z
35
Led
2042452D
Drive axle assy.
2825849S
Gear box assy
2825826T
Clutch
2930536R
Leaf spring assy
2825827U
26
Gear 32T assy
2825653N
27
Gear 30T assy
2825655Q
29
2042976Z
page 10-62
Micro switch
2825265J
page 10-64
Pulse disc sensor
2975505J
Stack mechanism unit
2825432Z
page 10-60
rev. 1.0 - 12/2009
combined order
number:
2825828V
10-65
075.1
Service Manual
10.5.8 Specifications High Capacity Vertical Stacker

Model
HCVS-1
Type
high capacity vertical stacker

Suitable for all kinds of mail sets that consist of at least one 80 grams
envelope and one folded document (80 gram).
Power consumption
Low voltage supplied by the inserter system.
Approvals
EMC Certificate conform EMC-Directive.

FCC Certificate conform 47CFR, part 15.
UL Listed I.T.E. (Information Technology Equipment),
conform UL-IEC 60950-1, file: E153801.
Conform NEN-EN-IEC 60950-1 and derivatives.
Height
Width
length
550 mm(21.7 inch)

440 mm (17.3 inch)
360 mm (14.2 inch)
Weight
12 kg (26.5 lbs)
Noise level
See 8.1 Machine specifications on page 8-1
Operating temperature
10C - 40C (50F-104F)
Humidity
30%-80%
Stacker capacity
325 envelopes, depending on application
10-66
rev. 1.0 - 12/2009
2825918P
WIRING
2
1
TX LOC
Connector B for backward

compatibility
ID TAG
2994504Z
CLOSER SOLENOID
EJECT SOLENOID
2
1
1
2
2
1
4
3
2
1
6
5
4
3
2
1
10
9
8
7
6
5
4
3
2
1
SEE SHEET 2
RX COLLATOR
2
1
8
7
6
5
4
3
2
1
CLUTCH CLUTCH FINGERS

Folder
SOLENOID
Folder
Reverse Forward
TX CLOSER
Inter
Connect
J650
J1200
B*
J700
J1201
J502
5
4
3
2
1
J603
J602
J601
J600
MAIN
PULSEDISC
2042819L
5
4
3
2
1
12
11
10
9
8
7
6
5
4
3
2
1
J501
J101
J100
J904
J604
J500
TX EXIT
RX EXIT
2
1
TX FLAP
READING
HEAD
ASSY
2989434T
TX ENV.TRACK
2
1
RX ENV.TRACK
1
2
2
1
FRONT COVER
TOP COVER
2989056Z
2989056Z
J1000
J904
5
4
3
2
1
4
3
2
1
11
10
9
8
7
6
5
4
3
2
1
RX LOC
RX FLAP
1
2
1
2
USB DEVICE
+24V
COMMUNICATION
HORUS BOARD
SLOTTED
SWITCH
FT1
2975505J
RX READING
HEAD
SLOTTED
SWITCH
FT2
2975505J
J1120 J1102
CLUTCH FT1
CLUTCH FT2
J1100
J802
1
2
MOTOR
PAPERSTOP
SLOTTED
SWITCH
PAPERSTOP2
2975505J
SLOTTED
SWITCH
PAPERSTOP1
2975505J
SEE SHEET 3
1
2
3
4
5
6
7
8
SEALING SOLENOID
CLUTCH
Env.track
1
2
3
4
5
3 7 4
1
2
3
2
1
3
2
1
Inter
Connect
J102
J801
J800
J701
INPUT: 100 - 120 VAC 3.15A

200 - 240 VAC 1.5A
50/60 Hz
OUTPUT: + 24 V
4.5A
POWER SUPPLY
Sealing liquid sensor

assy. 2825246P
J903
J902
J901
1,2,3X
On J902
On J901
1
2
3
4
5
6
1
2
3
4
5
6
7
8
ADJ
+V
+V
+V
COM
COM
(AC)
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
10
2825917N
WIRING
BIG FEEDER (HCF)
OPTIONAL
3 4
5 6
3 4
5 6
3 7 4
5
Motorboard
MAXI FEEDER
OPTIONAL
TMU 1
2790171C
DFC FEEDER1
TOP
8 9 10
72
74
START
RUN
1
2
J1
S, T
A, L, Y
B*
S, T, U
1
2
3
4
5
6
7
8
2
4
MAINS LEAD
PLUG TYPE:
COUNTRY SPECIFIED
EURO 2989051U
USA
2989052V
2989053W
UK
FUSE:
230V: 2.5 A (2975543Y)
110V: 5 A (2121549W)
POWER INLET 2989005W
CON8
J530
Z (all power wiring)
MOTOR
COLLATOR
TX COLLATOR
2825917N
2825916M
2825915L
2825914K
2989036D
2989034B
2989032Z
2989028V
2989024R
2989022P
2989020M
2989018K
2989010B
2994536H
2994530B
2975500D - 230V
2975540V - 115V
5251
54
2994522T
2994526X
CONNECTED TO
CONNECTOR:
K
SLOTTED
SWITCH
COLLATOR
2975505J
WIRING PARTNUMBER:
2994520R
55
INCLUDES: MAINS FUSE
J3
124
230V: 5F (2989006X)
115V: 20F (2121281S)
FEED
FEEDER1/2/3 *
115V: 2989407Q
230V: 2989406P
TX READ HEAD
1
2
RX FOLDER
2
1
TX FOLDER
1
2
RX COLLATOR
2
1
TMU 1
2790171C
DFC FEEDER1
TOP
8 9 10
FEED
3
2
1
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
rev. 1.0 - 12/2009

1
2
3
4
5
6
7
8
9
10
10.6
73
OPTIONAL
ACCESSORY
STACKER
Service Manual
075.1
Total view electronics sheet 1/3
10-67
10-68
Backlight
1
2
3
4
J101
J210
J100
J103
WIRING DISPLAY 2989082B
COLOUR DISPLAY
AND TOUCH SCREEN
2994510F
J104
DISPLAY BOARD
2994502X
Touch screen
WIRING 2994544R
1
2
3
4
J1200
J100
KEYBOARD
2994508D
MAIN BOARD
2825900V
10.7
4
3
2
1
075.1
Service Manual
rev. 1.0 - 12/2009
E
J502
COMMUNICATION
+24V
HORUS BOARD
R
J1102
J1120
1
2
3
J1100
1
2
3
4
5
USB DEVICE
1
2
3
4
5
1
2
3
4
5
6
7
8
COMMUNICATION BOARD
2992000R
J402
C
J401
B
J101
1
2
3
1
2
3
4
5
6
7
8
9
10
11
12
MAIN BOARD
2825900V
RS 232
USB BOARD
2992003U
TEL
CONNECTION BOARD
2992001S
USB
J101
USB
J105
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
6
7
8
9
10
11
12
A, C, F, G
2994532D
P, E, Q, B
D, R
2994534F
2994548V
(CONNECTIVITY DISABLED)
P, H
(CONNECTIVITY ENABLED)
CONNECTED TO
CONNECTOR:
CONNECTIVITY DISABLED
WIRING PARTNUMBER:
CONNECTIVITY ENABLED
1
2
3
4
5
6
rev. 1.0 - 12/2009

1
2
3
4
5
6
7
8
9
10
11
12
10.8
J403
J108
Service Manual
075.1
10-69
075.1
10-70
Service Manual
rev. 1.0 - 12/2009

DS-75 (075.1) Service Manual r1.0

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

DS-75 (075.1) Service Manual r1.0

Enviado por

Direitos autorais:

Formatos disponíveis

Service Manual

Revision: rev. 1.0 - 12/2009

rev. 1.0 - 12/2009

rev. 1.0 - 12/2009

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

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

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

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

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

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

rev. 1.0 - 12/2009

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

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

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

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

rev. 1.0 - 12/2009

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

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

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

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

rev. 1.0 - 12/2009

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

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

rev. 1.0 - 12/2009

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

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

rev. 1.0 - 12/2009

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

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

rev. 1.0 - 12/2009

Business Reply Envelope

Interface Standard Inserting Systems

Mail Piece Production Control

Double Feed Control

Optical Mark Recognition

Graphical User Interface

Printed Circuit Board

Human Machine Interface

Serial Communication System

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

rev. 1.0 - 12/2009

rev. 1.0 - 12/2009

Health, safety and environment

This machine must be operated by competent personnel.

Symbols on the machine

rev. 1.0 - 12/2009

Equipment produced after August 13,

rev. 1.0 - 12/2009

rev. 1.0 - 12/2009

Envelope support bracket

Collating the document set

Envelope exit process

rev. 1.0 - 12/2009

rev. 1.0 - 12/2009

Feed roller. Activated by the envelope track clutch CL8.

Lower insert roller.

Upper insert roller (in the upper unit).

Upper second ejection roller (in the upper unit).

Driven sealing track roller.

Counter roller for 22 (in the upper unit).

Upper sealing roller.

Lower reverse roller (in the upper unit).

Drive rollers for future use.