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IC 1000/IC 1825 and NDP 1000-4X/NDP18254X Imaging Module
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IC 1000/IC 1825 AND NDP 1000-4X/NDP18254X IMAGING MODULE
Installation and Servicing Guide
Unisys Proprietary This document is confidential and proprietary to Unisys Corporation. It is not to be used, reproduced, or disclosed outside Unisys without the written consent of Unisys Corporation. The information in this document is furnished for use by Unisys support personnel in servicing customers equipment, or by a customer under a license agreement with Unisys. This document is the property of Unisys. Upon termination of customers license to this material, it should be returned to Unisys Corporation, Global Customer Services, PO Box 500, Blue Bell, PA 19424. LIMITED RIGHTS - This document is technical data provided to the U.S. Government with limited rights pursuant to DFARS 252.2277013 and 252.2117015/FAR 52.22714 & 52.22719. Copyright 1998 Unisys Corporation. Unpublished Material - All rights reserved.
December 1998 Printed in USA 2983 7986204
Priced Item
IC 1000/IC 1825 AND NDP 1000-4X/NDP18254X IMAGING MODULE
Installation and Servicing Guide
Copyright 1998 Unisys Corporation. All rights reserved. Unisys is a registered trademark of Unisys Corporation. December 1998 Printed in USA 2983 7986204
Priced Item
The names, places, and/or events used in this publication are not intended to correspond to any individual, group, or association existing, living, or otherwise. Any similarity or likeness of the names, places, and/or events with the names of any individual, living or otherwise, or that of any group or association is purely coincidental and unintentional. NO WARRANTIES OF ANY NATURE ARE EXTENDED BY THIS DOCUMENT. Any product or related information described herein is only furnished pursuant and subject to the terms and conditions of a duly executed agreement to purchase or lease equipment or to license software. The only warranties made by Unisys, if any, with respect to the products described in this document are set forth in such agreement. Unisys cannot accept any financial or other responsibility that may be the result of your use of the information in this document or software material, including direct, special, or consequential damages. You should be very careful to ensure that the use of this information and/or software material complies with the laws, rules, and regulations of the jurisdictions with respect to which it is used. The information contained herein is subject to change without notice. Revisions may be issued to advise of such changes and/or additions. RESTRICTED Use, reproduction, or disclosure is restricted by DFARS 252.2277013 and 252.211 7015/FAR 52.22714 & 52.227-19 for commercial computer software. Correspondence regarding this publication should be forwarded to Unisys Corporation by addressing remarks to Product Information, Unisys Corporation, 41100 Plymouth Road, Plymouth, MI 48170 U.S.A. Comments about documentation can also be sent through e-mail to doc@unisys.com.
Unisys is a registered trademark of Unisys Corporation. All other terms mentioned in this document that are known to be trademarks or service marks have been appropriately capitalized. Unisys Corporation cannot attest to the accuracy of this information. Use of a term in this document should not be regarded as affecting the validity of any trademark or service mark.
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Contents
About This Guide ....................................................................................... Section 1. Operation and Components
IC 1000/IC 1825 Imaging Module ........................................ Operation ................................................................ Imaging Module Interfaces ........................................ Imaging Module Components .................................... NDP 1000-4X/NDP 1825-4X Imaging Module ..................... Operation ................................................................ Imaging Module Components .................................... Image Module Interfaces ........................................... 11 11 12 14 15 15 16 17 xv
Section 2.
Imaging Module Installation on a Document Processor

Document Processor Circuit Breaker Upgrade ..................... Unpacking the Imaging Module ............................................. Preparing the Document Processor ...................................... Installing the Imaging Module ............................................... Leveling the Machine ............................................................. Installing Microfilmer Drive Transfer Components ................ Drive Installation - TDC Microfilmer ...................................... Drive Installation - Unisys Microfilmer ................................... Microfilmer Air Hose Relocation ............................................ Drive Installation - No Microfilmer ......................................... Procedure A ............................................................ Procedure B ............................................................ Cooling Change Installation For the NDP 1000-4X/ NDP 1825-4X Imaging Module .................................................. Reject Pocket Assembly ........................................................ Top Cover Trim Installation ................................................... Area 1 ..................................................................... NIE/MJE .................................................................. High Speed Encoder Module ..................................... Unisys Microfilmer .................................................... TDC Microfilmer ....................................................... Installing Document Processor Interface Harnesses and Logic With an IC 1000/IC 1825 Imaging Module ............. 22 26 27 210 213 215 216 216 216 217 217 219 220 224 225 225 225 226 226 226 227
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Installing Document Processor Interface Harnesses and Logic With an NDP 1000-4X/NDP 1825-4X Imaging Module ............................................................................... Circuit Breaker Installation on a Dual Imaging Module ......... Unpacking the U4 or JPEG Electronics Gate and CCITT Gate .................................................................................... U4 Electronics Gate .................................................. JPEG Electronics Gate .............................................. Installing the U4 Electronics Gate .......................................... Installing the U4 Electronics Gate PCBAs .............................. Connecting the U4 Image Cables .......................................... Secondary AC Harness ............................................. IM Fan Harness ........................................................ 24-Volt Bias Harness ................................................ Document Processor Interface Cable ......................... Five-Volt Power Supply Ground Cable ......................... Five-Volt DC Sense Harness ....................................... Image Lift Power Cable ............................................. 15-Volt Harness ........................................................ Five-Volt Power Supply Cables ................................... Video Cables ............................................................ Lamp Power Supply Interface Cable ........................... Installing the JPEG and CCITT Electronics Gate .................... Connecting the External JPEG Image Cables ........................ Lamp Controller Interface (DTI) Cable ......................... Lamp Controller (Auxiliary 15-Volt) Power Cable .......... Secondary AC Supply Harness .................................. 15-Volt Camera Harness ........................................... Document Processor Interface Cable ......................... 24-Volt Sense Harness .............................................. Logic Ground Cable .................................................. POL Fiber Optic Cable ............................................... CAR Data Cable ........................................................ Video Cables ............................................................ Installing Dual Imaging Module Interface Cables .................. Installing ICS Components ..................................................... U4 and JPEG IM Power Up and Check Out ............................ Dual IM Power Up and Check Out ..........................................
232 236 239 239 240 241 249 251 251 253 254 255 256 257 258 259 260 261 263 264 275 276 276 276 278 278 279 280 280 281 281 282 287 288 289
Section 3.
IC 1000/IC 1825 Imaging Module Components
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Section 4.
Maintaining the IC 1000/IC 1825 Imaging Module

Maintenance Philosophy ........................................................ Field Replacement Modules (FRMs) ...................................... Electronics Gate FRMs .............................................. Imaging Module FRMs in the Document Processor ...... Imaging Module FRMs Removal and Replacement Procedures ........................................................................ U4 Cables and Harnesses ......................................... JPEG Cables and Harnesses ..................................... Camera Box ............................................................ Circuit Breakers ....................................................... Energy Dump Fan ..................................................... 15-Volt Power Supply ............................................... Image Camera PCBA Assemblies .............................. IM Cooling Fan ......................................................... Lamp and Enclosure ................................................. Lamp Control PCBA .................................................. Lamp Cooling Fan .................................................... Lamp Power Supply ................................................. Power Control PCBA ................................................. Shutter Sensor and Actuator ..................................... Track Components ................................................... Beam of Lights ................................................ Bearing Housing and Shaft Assembly ................ Belts ............................................................... Cover Interlock Switch ...................................... Crown Roller Assembly ..................................... Front Frame and Window Assembly ................... Idler Assembly ................................................. Front Left Idler Pulley ............................... Front Right Idler Pulley ............................. Rear Frame and Window Assembly .................... Track Interlock Switch and Actuator .................. U4 Electronics Gate FRMs ..................................................... Backplane ............................................................... Cables and Harnesses .............................................. Card Guide .............................................................. Ejector .................................................................... 5-Volt Power Supply ................................................. Fan Filter ................................................................. Fans ....................................................................... PCBAs .................................................................... JPEG Electronics Gate FRMs ................................................. Backplane ............................................................... Cables and Harnesses .............................................. Card Guide .............................................................. Ejector .................................................................... 5/15 Volt Power Supply ............................................ Fan Filter ................................................................. 41 42 43 43 44 44 46 49 413 414 415 419 421 422 425 427 429 432 433 434 434 436 437 438 438 439 440 440 441 442 443 444 444 447 448 449 450 452 453 455 458 458 460 461 463 465 467
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Fans ........................................................................ PCBAs ..................................................................... Clock PCBA ..................................................... Video Interconnect PCBA .................................. Lamp Controller/DTI Interface (LC/DTI I/F) PCBA .......................................................... Imaging Module FRMs in the Document Processor ............... Image Button Light ................................................... Image Circuit Breaker ............................................... Image Interface PCBA ............................................... Image Power Line Filter ............................................. Preventive Maintenance .........................................................
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Section 5.
Maintaining the NDP 1000-4X/ NDP 1825-4X Imaging Module

Front Camera Board/Lens Assembly .................................... Calibrating the Cameras ........................................................ Rear Camera Board/Lens Assembly ..................................... Front Camera Head ............................................................... Rear Camera Head ................................................................ Thermal Sensor ...................................................................... Light Sensor Assembly (Front or Rear) .................................. Lamp Socket Assembly (Front or Rear) ................................. Lamp Cover Interlock Switch ................................................. Lamp Control Board ............................................................... Logic/Lamp Power Supply ..................................................... Camera (Linear) Power Supply (DP 1000, DP 1800 Front and Rear) ........................................................................... Backplane (DP 1000 and DP 1800) ...................................... Power Supply Fan .................................................................. Logic Gate Fans ..................................................................... Track Components ................................................................. Beam of Lights ......................................................... Bearing Housing and Shaft Assembly ......................... Belts ....................................................................... Cover Interlock Switch .............................................. Crown Roller Assembly ............................................. Idler Assembly ......................................................... Front Left Idler Pulley ........................................ Track Interlock Switch and Actuator ........................... 52 55 58 510 514 519 520 523 526 529 530 533 535 539 539 541 542 543 545 547 547 549 549 551
Appendix A. Special Engineering Instructions and Tests and Adjustments Glossary ....................................................................................................... Index ..............................................................................................................
1 1
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11. 12. 13. DP 1XXX Document Processor With IC 1XXX Imaging Module .................... Imaging Module System Interfaces ......................................................... NDP 1XXX Document Processor With NDP 1000-4X/NDP 1825-4X Imaging Module (Dual IM) ................................................................... Circuit Breaker Housing ......................................................................... Document Processor Electrical Connections ............................................ Image Module Shoulder Bolt Connections ................................................ Bolting and Alignment of 8-Pocket Modules ............................................... Timing Belt Installation ........................................................................... Idler Arm and Pulley Installation .............................................................. Relocating the Air Outlet Hose (Inside Module Looking Out) ....................... Relocating the Air Outlet Hose (Outside Module Looking In) ....................... Detail of Air Flow Diversion Adapter Location ........................................... Quarter Panel Foam Removal ................................................................. BOL/Interlock Harness Installation .......................................................... Breaker Panel Wiring ............................................................................. Image RFI Filter ..................................................................................... BOL/Interlock Harness Installation .......................................................... Breaker Panel Wiring ............................................................................. Image RFI Filter ..................................................................................... Electronics Gate and Plenum .................................................................. Electronics Gate Mounting Rails .............................................................. Center Frame Fan Panel ......................................................................... Fan Panel ............................................................................................. 5-Volt Power Supply ............................................................................... Frame Drilling Locations ........................................................................ Secondary AC Harness Routing .............................................................. IM Fan Harness Routing ......................................................................... 24-Volt Bias Harness Routing ................................................................. Document Processor Interface Cable Routing .......................................... 5-Volt Power Supply Ground Cable Connection ......................................... 5-Volt DC Sense Harness Routing ........................................................... Image Lift Power Cable Routing .............................................................. 5-Volt Power Supply Cable Connections .................................................. Video Cable Routing .............................................................................. Lamp Power Supply Interface Cable Routing ............................................ Location of Lamp Controller Interconnect PCBA Interface and Video Interconnect PCBAs ........................................................................... AC Line Filter Location ........................................................................... Correct Position of Bus Bars .................................................................. JPEG Wiring Diagram ............................................................................. EMI Ground Strap Locations ................................................................... Location of External Cable Connectors .................................................... 12 13 15 23 28 211 213 215 218 220 221 222 224 228 229 230 233 237 238 240 241 243 244 246 247 252 253 254 255 256 257 258 260 262 263 265 266 267 271 273 275
21. 22. 23. 24. 25. 26. 27. 28. 29. 210. 211. 212. 213. 214. 215. 216. 217. 218. 219. 220. 221. 222. 223. 224. 225. 226. 227. 228. 229. 230. 231. 232. 233. 234. 235. 236. 237. 238.
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239. 240. 241. 242. 243. 244. 245. 31. 32. 33. 34. 35. 41. 42. 43. 44. 45. 46. 47. 48. 49. 410. 411. 412. 413. 414. 415. 416. 417. 418. 419. 420. 421. 422. 423. 424. 51. 52. 53. 54. 55. 56. 57. 58. 59.
JPEG Lamp Controller Power and Interface Cable Routing ......................... JPEG 15-Volt Camera Power Cable Routing .............................................. JPEG 24-Volt Bias Harness Routing ......................................................... NDP 1150 Backplane Connectors ........................................................... NDP 1825 Backplane Connectors ........................................................... NDP 1150 Dual Image Wiring Block Diagram ........................................... NDP 1825 Dual Image Wiring Block Diagram ........................................... Component Locator (Front) ..................................................................... Component Locator (Rear) ..................................................................... Track Components ................................................................................ U4 Electronics Gate PCBA Locator JPEG Electronics Gate PCBA ............... JPEG Electronics Gate PCBA Locator ...................................................... Camera Box .......................................................................................... Optical Tower Removal .......................................................................... Energy Dump Fan .................................................................................. 15-Volt Power Supply ............................................................................. Image Camera PCBA Assembly ............................................................... IM Cooling Fan ...................................................................................... Lamp and Enclosure .............................................................................. Lamp Control PCBA ............................................................................... Lamp Cooling Fan .................................................................................. Lamp Power Supply ............................................................................... Power Control PCBA .............................................................................. Shutter Sensor ...................................................................................... Track Components ................................................................................ Belt, Idler, and Tensioner Locations ........................................................ Front Frame and Window Assembly ......................................................... Rear Frame and Window Assembly .......................................................... Backplane ............................................................................................. 5-Volt Power Supply ............................................................................... Image Gate Fans ................................................................................... Inserting a PCBA ................................................................................... JPEG Backplane Connectors ................................................................... JPEG Fans ............................................................................................ Image Circuit Breaker ............................................................................ Image Interface PCBA ............................................................................ Front Camera Board/Lens Assembly and Camera Head Cable (Overhead View) ................................................................................................ Inserting a Pen into the Top Hole of the Camera Frame and Window Assembly .......................................................................................... Pulling the Camera Frame and Window Assembly Out ............................... Rear Camera Head and Cable (Overhead View) ......................................... Front Camera Head, Cable, and Fiber Optic Cables (Overhead View - Fiber Optic Cable Covers Removed) ............................................................ Lamp Cover and Fiber Optic Cable Cover ................................................ Front Light Sensor Assemblies ................................................................ Rear Camera Head and Cables (Overhead View - Fiber Optic Cable Covers Removed) ......................................................................................... Lamp Cover and Rear Fiber Optic Cable Cover .........................................
276 278 279 283 284 285 286 31 32 32 33 34 49 410 414 416 419 421 422 425 427 429 432 433 435 437 439 442 445 450 453 455 459 468 473 475
53 56 57 59 511 512 513 515 516
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510. 511. 512. 513. 514. 515. 516. 517. 518. 519. 520. 521. 522. 523. 524. 525. 526. 527. 528. 529. 530. 531.
Rear Light Sensor Assemblies ................................................................ Lamp Cover and Thermal Sensor ............................................................ Lamp Cover and Fiber Optic Cable Cover ................................................ Light Sensor Assembly Connector .......................................................... Lamp Cover and Lamp Socket Assemblies .............................................. Baseplate, Bracket, and Fan ................................................................... Lamp Cover and Lamp Cover Interlock Switch ......................................... Bracket ................................................................................................ Lamp Control Board .............................................................................. Logic/Lamp Power Supply ..................................................................... Logic/Lamp Power Supply Connector Identification .................................. Logic/Lamp Power Supply and Linear Power Supply ................................ Backplane ............................................................................................ DP 1000 Backplane Connectors ............................................................. DP 1825 Backplane Connectors ............................................................. Logic Gate Fans .................................................................................... Track Components ................................................................................ Beam of Light Pairs ............................................................................... Bearing Housing and Shaft Assembly and Belts ....................................... Belt, Idler, and Tensioner Locations ........................................................ Crown Roller Assembly and Belts ............................................................ Front Left Idler Pulley and Belt and Tensioner Locations ...........................
517 519 521 522 524 525 527 528 529 531 532 534 536 537 538 540 541 542 544 546 548 550
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21. 22. 23. 24. 25. 26. 27. 28. 29. 211. 212. 213. 214. 215. 216. 41. 42. 43. 44. 45. 46. 47. 48. 49. A1. NIE Power Supply Connection ................................................................. AC Control Cables ................................................................................. IM Shoulder Bolt Usage .......................................................................... PROM and PCBA Minimum Levels ........................................................... Added AA Gate Backplane Wiring ............................................................ Added AA Gate Backplane Wiring Changes For Dual IM DL1/DL2 Units ...... Added AA Gate Backplane Wiring Changes For Dual IM DL3 Units .............. Added AA Gate Backplane Wiring Changes For Dual IM DL3 Units .............. PROM and PCBA Minimum Levels ........................................................... U4 Electronics Gate PCBA Locations ...................................................... POL Cable Connections ......................................................................... EMI 5-Volt Power Supply Connections ..................................................... Internal Backplane Cable and Harness Connections .................................. Harnesses Attached to the PS Cover ...................................................... AC Harnesses ....................................................................................... U4 Imaging Module Cables and Harnesses .............................................. JPEG Imaging Module Cables and Harnesses ........................................... U4 Image Gate Cables and Harnesses .................................................... PCBA Jumper Settings ........................................................................... JPEG Cables and Harnesses to Disconnect ............................................. JPEG Image Gate Cables and Harnesses ................................................. Cables and Harnesses to Disconnect from the PSU Cover Panel ............... Cables and Harnesses to Reconnect to the Internal PSU Cover Panel ........ JPEG PCBA Jumper Setting .................................................................... Imaging Module SEIs and T&As .............................................................. 28 29 212 231 231 234 234 235 235 249 250 261 268 269 269 44 46 447 456 458 460 465 466 470 A1
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About This Guide

This guide provides procedures for installing and servicing these modules: Image Item Processing System (IIPS) IC 1000, IC 1000-J, IC 1800, IC 1825, IC 1825-J, and IC 1800-JU Imaging Module (IM) References to the Imaging Modules are labeled IC 1XXX throughout this guide. References to the document processors DP 1000, DP 1800, and DP 1825 are labeled DP 1XXX throughout this guide. NDP 1000-4X/NDP 1825-4X Imaging Module (dual image) References to the NDP document processors are labeled NDP 1XXX throughout this guide.
Purpose
This guide provides an overview of the IM and dual IM components and their maintenance. It also provides installation procedures. Drawings showing the locations of the serviceable modules are included.
Scope
For the IM, this guide applies to the IC 1XXX Imaging Module. Other components of IIPS are documented in separate guides. For the dual IM, this guide applies to the NDP 1000-4X/NDP 1825-4X Imaging Module. Other NDP components are documented in separate guides.
Audience
This guide is for Unisys Client Service Engineers (CSEs) who install and service the IM or dual IM.
Prerequisites
Personnel using this guide should have a basic understanding of IIPS and NDP. IIPS information is available in the Image Item Processing System (IIPS) Servicing Guide: Maintenance.
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Organization
This guide consists of the following sections and appendixes. In addition, a glossary and an index appear at the end of this guide. Section 1. Operation and Components This section introduces the modules, describes their operation, and provides a description of the major components. Section 2. Imaging Module Installation on a Document Processor This section provides procedures for installing the IM or dual IM into an existing or factory-prepped document processor. Section 3. IC 1000/IC 1825 Imaging Module Components This section describes the documentation shipped with the IM or dual IM and the technical documents related to the module, and provides illustrations with locations of the major components for the IM. Section 4. Maintaining the IC 1000/IC 1825 Imaging Module This section provides detailed procedures used in IM maintenance. Topics include removal and replacement procedures for field replaceable modules (FRMs), tests and adjustments, and preventive maintenance. Section 5. Maintaining the NDP 1000-4X/NDP 1825-4X Imaging Module This section provides detailed procedures used in dual IM maintenance. Topics include removal and replacement procedures for field replaceable modules (FRMs). Appendix A. Special Engineering Instructions and Tests and Adjustments This appendix provides special engineering instructions (SEIs) and tests and adjustments.
Results
Having read this guide, you should understand how to install and service the IM and dual IM.
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About This Guide
Related Product Information

The following documents complement this guide. DP 1000/DP 1800/DP 1825 Servicing Guide: Parts Catalog (2983 9396) This guide provides illustrations and field replacement unit (FRU) part numbers for all DP 1000/DP 1800/DP 1825 FRMs. DP 1800 Servicing Guide: Maintenance Procedures for DL1 and DL2 (2983 8653) This guide provides maintenance procedures for the DL1 and DL2 versions of the DP 1800 Document Processor. DP 1825 Installation Guide (2983 8984) This guide provides procedures for the installation and maintenance of the DP 1825 Document Processor. IC 1000/IC 1825 Imaging Module Operations Guide (2983 8679) This guide provides operation procedures for the Imaging Module. Image Item Processing System (IIPS) Servicing Guide: Diagnostic Procedures (2983 4706) This guide provides diagnostic procedures for IIPS. Image Item Processing System (IIPS) Servicing Guide: Maintenance (2983 8091) This guide provides maintenance procedures and maintenance test routines (MTRs) for IIPS. IR 9210 Courtesy Amount Read (CAR) Module Capabilities Overview (2946 1351) This document provides an overview of CAR module operations. It also describes the CAR module hardware, application software, and important preinstallation considerations. IR 9210 Courtesy Amount Read (CAR) Module Servicing Guide: Parts Catalog (2496 1468) This manual illustrates the components of the CAR module and identifies part numbers. IR 9210 Courtesy Amount Read (CAR) Module Site Preparation Data Sheet (2983 9263) This document presents the information necessary for the customer to prepare the site for the CAR module. It describes the requirements for space, environmental control, and power.
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About This Guide
IR 9210/IR 9220 Courtesy Amount Read (CAR) Servicing Guide: Diagnostic Procedures (2983 7853) This manual provides diagnostic procedures and maintenance test routines for the CAR module. IR 9210/IR 9220 Courtesy Amount Read (CAR) Servicing Guide: Installation and Maintenance (2983 7804) This guide provides an introduction to the CAR module, installation instructions, and removal and replacement procedures. NDP Capabilities Overview (3998 1956) This document provides an overview of NDP operations. It describes the document processors and modules, system software, enhancements, and important preinstallation considerations. NDP Operations Guide (3998 1923) This guide provides operation procedures for the NDP document processor, including the NDP PC, HSEM, and the NDP 1000-4X/NDP 1825-4X Imaging Module. NDP Servicing Guide: Hardware Installation (3998 5585) This guide provides procedures for the installation of the Network Document Processor hardware. NDP Servicing Guide: Maintenance Procedures (DL3) (3998 5593) This guide provides the maintenance test routine (MTR) information for the NDP 1150 and NDP 1825 Document Processors. NDP Servicing Guide: Parts Catalog (3998 5601) This guide provides illustrations and field replacement unit (FRU) part numbers for all NDP FRMs. NDP/DP 1000/DP 1825 Servicing Guide: Analysis and Test Software (2983 9289) This guide provides information on the diagnostic programs available for the CSE to discover and resolve problems in the operation of the NDP and DP 1XXX document processors. NDP 1000-4X/NDP 1825-4X Imaging Module Image Capture Server Software Installation and Operations Guide (4326 4878) This guide provides procedures for installing the Image Capture Server software, running the Trace Function and Storage Connectivity Test, and running the Common Application Programming Interface Exerciser. The guide also describes the Communicates for the image platform.
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Section 1 Operation and Components

This section introduces the IC 1000/IC 1825 and NDP 1000-4X/NDP 1825-4X imaging modules and describes the operation and the major components of the modules.
IC 1000/IC 1825 Imaging Module

This subsection describes the operation, interfaces, and imaging module (IM) components.
Operation
The IM is composed of hardware and software that capture, digitize, process, compress, and package images as they pass through a document processor. Document images are captured as they are sorted. In a high-speed document processor, for a DP 1825 the sorting speed is 1,825 documents per minute (at a track speed of 300 inches per second). The sorting speed is 1,000 documents a minute (a track speed of 150 inches per second) for a DP 1000. As each document passes along the document processor track, an intense vertical stripe of light is directed to both sides of the document. The light contacts the document and is reflected to a set of mirrors. It is then focused through a lens and onto the camera printed circuit board assembly (PCBA). The camera PCBA measures the light reflected from the document in analog voltage values and then sends the data to the electronics gate submodule for processing, compression, and temporary storage. Image packets (made up of document image data) are then sent to the IR 9000 Series Storage and Retrieval Module for later retrieval by image workstations (IWSs). The images are used in image-based applications and may be printed. Note: For additional system-level information, refer to the Image Item Processing System (IIPS) Functional Overview.
Figure 1-1 shows the IM installed in a DP 1XXX Document Processor. The IC 1000-J Imaging Module, located on the DP 1000 Document Processor, and the IC 1825-J Imaging Module, located on the DP 1825 Document Processor, are positioned between the Area 1 module and the first pocket module. If your document processor also includes the optional microfilmer, the imaging module is located between the microfilmer and the first pocket module, as shown in Figure 1-1.
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Operation and Components
Figure 11. DP 1XXX Document Processor With IC 1XXX Imaging Module The IM performs the following functions within IIPS: Accepts User Sort Program (USP) commands and data from the document processor Captures document images Digitizes document images Performs image processing operations on document images Compresses document image data Stores image and document-specific data temporarily Transmits image and document data (image packets) to the SRM Accepts unit management commands from the host processor Obtains configuration information from the host processor and SRM
Imaging Module Interfaces

The IM communicates with four IIPS modules: Document processor Host processor SRM Courtesy amount read (CAR) module (an option with IIPS)
The document processor forwards transport status requests to the IM. Imaging statistics, image system status, diagnostic information, and responses to the USP requests are passed from the IM to the document processor. The IM sends image data and file manipulation requests to the SRM through a fiber optic link. The SRM passes file manipulation responses and initialization data to the IM.
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The IM receives system configuration management requests from the host processor through the SRM. When the CAR module is installed, the CAR port board is located in the electronics gate submodule. The IM sends image segments to the CAR port board. A video cable sends the image segment from the CAR Port board to the Pixel Unit board inside the CAR module. Figure 1-2 shows how the IM is connected to other IIPS components.
Figure 12. Imaging Module System Interfaces
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Imaging Module Components

The IM is made up of two major components, the camera submodule and the electronics gate submodule. The camera submodule is located in a transport module of the sorter, between the microfilmer (if one is present) and the first pocket module. The electronics gate submodule is located in the lower portion of the first pocket module. There are two different electronics gates available for image compression and decompression in the IM, U4 and Joint Photographic Experts Group (JPEG). The U4 system, a Unisys proprietary compression/decompression system, has a 5-volt power supply that is mounted outside the imaging module electronics gate. It distributes five volts direct current (VDC) to the electronics gate through a fan panel and electromagnetic interference (EMI) shield by way of several cables. The industry standard JPEG system also uses a 5-volt power supply. This power supply, however, is mounted inside the electronics gate and EMI shield that protrudes through the frame of the adjoining module. The power supply distributes five VDC to the electronics gate by way of Teflon-coated copper ribbon cables. Note: JPEG is the only electronic gate available in the DP 1000 document processor.
The camera submodule, lamps, and electronics gate submodule each have their own power supplies.
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NDP 1000-4X/NDP 1825-4X Imaging Module

This subsection describes the operation, interfaces, and dual IM components.
Operation
The dual IM is composed of hardware and software that captures, digitizes, processes, compresses, and packages image as they pass though a document processor. Document images are captured as documents are sorted. The NDP 1825 has a track speed of 300 inches per second (approximately 1825 images per second) and the NDP 1150 has a track speed of 150 inches per second (approximately 1000 images per second). The dual IM illuminates and captures a digital image of each document that passes down the transport. The image is framed, compressed, and then retrieved by an Image Capture Server (ICS) for subsequent delivery to an Image File Server (IFS). The document processor also provides document-related information to the ICS through the dual IM. Figure 1-1 shows the dual IM installed in a NDP 1XXX Document Processor.
82 04
7 6 5 4 3 2 1
Legend
1. PC module 2. Basic unit 3. RMJE or FMJE 4. High Speed Encoder (NDP 1150 only) 5. Microfilmer 6 Imaging module 7. 8-pocket modules (Basic module, add-on module, (and controller module)
Figure 13. NDP 1XXX Document Processor With NDP 1000-4X/NDP 1825-4X Imaging Module (Dual IM) The dual IM also has provisions for providing video to an optional Courtesy Amount Read unit.
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Imaging Module Components

The dual IM is a transport module of the NDP 1XXX. It is the last transport module before the pocket modules. If a microfilmer is present in the system, the dual IM provides the belt drive to its transport. The dual IM lamps and solid state cameras are mounted above the transport baseplate. The lamps are located under a hinged enclosure at the front of the module. The transports top cover has an interlock that dims the lamps when the cover is raised. The lamp enclosure cover also has an interlock that extinguishes the lamps when the operator raises the lamp cover to change the lamps or the CSE raises the lamp cover to service components under the cover. The dual IM uses four standard projection lamps (two per camera). The cameras image the document through glass windows in the transport. As each document passes along the document processor track, an vertical stripe of light is directed to both sides of the document. The solid state image camera views the illuminated documents and scans the document as a series of vertical stripes. The signals from the camera are sent to electronic components in the logic gate that is located in the base of the module. The electronic components correct the image data for variations in illumination and camera sensitivity. The images are framed, finding the top, bottom, leading, and trailing edges. Under direction of the User Sort Program (USP), images are then compressed as black/white renditions by Consultative Committee on International Telephone and Telegraph (CCITT) Group 3 or Group 4 compression and/or as grayscale renditions with JPEG baseline compression. The dual IM is capable of providing up to two compressed renditions of the front image and one rendition of the rear image per document. Two compressor types are available as options for the rear image, however, only one may be selected at a time. Image data is retrieved by the ICS for subsequent delivery to an IFS. The ICS controls the document-to-document operations and information transfers of the dual IM. The power supplies for the dual IM are located in the base of the transport module. One supply provides 5V power for the logic and power for the lamps. A linear supply provides power for the camera and analog circuits. When the Hardware CAR module is installed, the CAR Port board is added to the dual IM electronics gate. The CAR Port board provides the processed image stream that the CAR unit requires. The CAR module for the NDP 1150 is located in the pocket module of the transport while the CAR module for the NDP 1825 is in a stand-alone cabinet. The ICS controls the operations of the CAR module through a differential SCSI link. If CAR-ICR is installed, JPEG snippet compressors are installed in the logic gate to provide the high resolution JPEG image required by this reader. The image snippets size and position are controlled by the application software. The snippets are stored on the ICS or IFS for retrieval by the CAR-ICR read system.
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Image Module Interfaces

The dual IM is composed of the transport module and the ICS. These communicate with the external environment through the following interfaces:
Document processor interface Image File Server interface Courtesy Amount Read interface (optional for HardCAR only)
The document processor provides document related information such as MICR codelines to the ICS. In turn, image system status and diagnostic information is passed back to the document processor. The ICS transfers file information to the Image File Server for long term storage and distribution over a dedicated LAN connection. The HardCAR Port board provides the processed image stream that the CAR unit requires. The ICS controls the operation of the HardCAR module through a differential SCSI link.
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Section 2 Imaging Module Installation on a Document Processor

This section provides a detailed explanation of procedures for installing the IC 1000/ IC 1825 Imaging Module (IM) or NDP 1000-4X/NDP 1825-4X dual Imaging Module (dual IM) into an existing or factory-prepped DP 1XXX or NDP 1XXX Document Processor. An existing Document Processor is one that has already been installed at a customer site in which imaging will now be added. A factory-prepped Document Processor is one that is shipped to the customer ready to have imaging installed. The DP 18XX Document Processors must have identification plates bearing a serial number 250 or higher. This signifies that the unit is at least Design Level 1 (DL1). All DP 1000s can have imaging installed. The IM or dual IM is to be located just before the reject pocket. Because of the many configurations of machines, some procedures in this section may not be required at each installation. The term basic unit is used to refer to the portion of the machine before an IM or dual IM, whether it is a microfilmer, a non-impact endorser (NIE) module, or a standard Area 1. The intent of this installation procedure is to break apart the document processor, install the IM or dual IM into the document processor, and run checks in the shortest time. The module can then be completed and brought up to full working level when time permits. This allows a customer to have quicker access to a machine which may be needed sooner than otherwise possible if all of the installation and check out were to be completed at one time. The following tasks may be completed prior to the actual installation of the IM or dual IM since they serve to make the document processor image ready: Customer installation of a 75 ampere circuit breaker on the power line for the DP 18XX document processor or a 60 ampere circuit breaker for the DP 1000 or NDP 1XXX document processor. Refer to the IC 1825 Imaging Module Site Preparation Data Sheet and see Document Processor Circuit Breaker Upgrade, the next topic in this section. The document processor cannot capture images if this task has not been completed. Circuit breaker upgrade (if required). Four-pocket to eight-pocket upgrade. Refer to special engineering instruction (SEI) 4139 5260. Note: Refer to the IR 9210/IR 9220 Courtesy Amount Read (CAR) Module Servicing Guide: Installation and Maintenance for instructions on installing the CAR Port board and the video cables that connect the CAR Port board to the CAR module.
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Document Processor Circuit Breaker Upgrade

DP 1800 Document Processors with serial numbers 330274069 and lower and DP 1000 Document Processors with serial numbers 372521930 and lower must have the entire circuit breaker box replaced. A distinguishing feature of the units requiring this change is to check the Area 1 circuit breaker panel. If the label for the breaker in the upper left corner of the panel is C/M Main, the unit needs to be replaced for image. This upgrade can be done in advance of the IM installation without affecting the normal operation of the document processor except for the downtime required to do the work. If the upgrade is not required, go to Unpacking the Imaging Module later in this section. Otherwise, refer to the following instructions and Figure 2-1. Use kit UC 201801 (3305 7571).
WARNING
Shut off electrical power to the document processor before proceeding with installation. Injury may result from electrical shock. The document processor is hard-wired to the facility power supply. Power must be shut off from the facility circuit breaker panel. Check to be sure power has been shut off before proceeding.
1. 2. 3.
Remove the Area 1 rear panel and the left end panel and set them aside. Open the front panel of the circuit breaker box in the Area 1 module at the rear of the machine. Measure the voltage across the two top lugs on the basic unit circuit breaker (CBBU) and the control module circuit breaker (CBCM), if present. If the voltage is not zero, do not proceed until power is removed from the line. Remove the sheet metal cover from the bottom of the radio frequency interference (RFI) filter located on the back panel of the breaker housing. Remove the three power leads from the terminals on the bottom end of the filter. Set the hardware aside for later reassembly. Loosen the black flexible conduit from the metal bulkhead, and pull the three wires and conduit out of the box. Remove the plastic cover mounted at the top of the RFI filter. Remove the two line leads from the output terminals of the filter. If present, disconnect the control module power cable from its circuit breaker, and remove the cable completely from the housing. See Figure 2-1.
4. 5. 6. 7. 8.
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Figure 21. Circuit Breaker Housing 9. Remove the two screws from the rear of the document processor that serve as pivots, thereby disconnecting the circuit breaker panel from the housing. Lay the panel on the floor or on a box behind the document processor as far as the harness length will allow.
10. Remove the screws securing the circuit breaker housing to the frame. Remove the green/yellow wire frame ground from the housing. Set aside the hardware for later reassembly. 11. Remove the black plastic conduit fitting from the old housing. 12. Remove all connections of the input cables going to the circuit breakers, and label these wires to ensure proper reinstallation. 13. Remove the strain relief bushings from the old panel. 14. Locate the new housing supplied with the upgrade kit, and orient it beside the housing. Attach the black plastic conduit connector and the strain relief cable clamps to the bottom of the new housing. 15. Remove the RFI filter from the back surface of the old housing. Relocate the filter inside the new housing with the two LOAD terminals facing the open end of the housing, and secure with three washers and nuts.
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16. Locate and secure the black terminal strip to the left inside wall of the housing. 17. Locate the two 11-inch long, 6-AWG white jumpers and the one 6-AWG, green/yellow ground jumper supplied with the kit. Connect the two white wires to the two input terminals on the top end of the filter marked LINE, using the hardware previously removed. 18. Secure the ground wire to the ground terminal of the filter. 19. Connect the other ends of the two input jumpers to the top positions of the terminal strip. 20. Position the new housing inside the document processor frame and secure with hardware previously removed. Note: It may be necessary to bend the item counter terminals away from the housing and wrap them with several turns of electrical tape to avoid an electrical short between the terminals and the item counter.
21. Feed the three leads of the power input cable through the plastic fitting on the housing. If the plastic conduit is too long, cut off the excess. Connect the conduit to the fitting. 22. Connect the two line leads of the input cable to the bottom of the terminal strip on the side wall, using the lugs from the previous hook-up. Connect the lugs using a flat washer on each side, and a lock washer. 23. Connect the ground conductor to the ground point on the right wall of the housing, CBGRD-2A, along with the other end of the ground jumper attached to the filter. The ground conductor in the power cord must have more slack than the two HOT leads, so that if the power cable is pulled, the ground wire is the last one to break. 24. Reattach the green/yellow wire frame ground (previously removed from the old housing) to the new housing. 25. Use the following procedure to transfer the entire bank of circuit breakers from the old panel to the new panel: a. b. Loosen the entire set of breakers, fuse(s), and the terminal strip. Transfer all to the new panel. Do one of the following: c. If a control module is not present, skip to Step 25c of this procedure. If a control module is present, locate the new control module breaker provided with the kit. Mount it at the appropriate opening in the bottom row.
Transfer any plugs used on the old panel to fill unused openings on the new panel. Verify that all wires are firmly and completely mounted to the breaker terminals.
26. Refer to wiring instructions 2494 0835 and 3135 7270 for the proper wiring of the new control module breaker. 27. Position the new panel in the new housing and secure in place with the two screws previously removed.
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28. Replace the Area 2 AC harness and the control module AC power harness (if present) with the new versions supplied with the upgrade kit. The longer Area 2 harness allows for the extra length to go through the IM. The control module harness has new terminals for the new circuit breaker. Refer to schematic sheet 03.05.XX for the harness connections. Note: If complete image installation is being performed, do not route the control module AC power harness until after the IM is installed.
29. Route the harnesses removed in step 11 through the strain relief bushings and attach to the proper terminals according to labeling done at the time of removal. 30. Install the two main input jumpers feeding the main circuit breaker to the load terminals of the RFI filter, using the hardware previously removed. 31. Do one of the following: Complete the image installation: Continue with Unpacking the Imaging Module, next in this section. Do not complete the image installation at this time: a. b. c. d. e. Perform the DP 1800 pre-power on check out procedure. Refer to Section 2, Installation, in the DP 1000/DP 1825 Operations Guide. Close the circuit breaker panel and reset all breakers. Perform the DP 1800 power on check out procedure. Refer to Section 2, Installation, in the DP 1000/DP 1825 Operations Guide. Install the left-end panel and the rear panel. Verify correct operation.
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Unpacking the Imaging Module

Use the following procedure to unpack the IC 1000/IC 1825 IM or NDP 1000-4X/ NDP 1825-4X (dual) IM:
WARNING
Use two or more trained Unisys personnel to move the module off of the pallet. Failure to do so may result in injury.
1. 2. 3. 4. 5. 6. 7. 8.
Cut the two straps around the outside of the box. Lift the box off of the unit. Remove the clear plastic cover. Unbolt and remove the piece of wood from the front of the pallet and unbolt the holding clamp on the side of the pallet. Remove the front and rear panels from the IM or dual IM. Slide the module off the pallet onto the floor. Inspect the module for damage before installing. Record comments in a log book. Open the module top cover, and remove all packing materials.
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Preparing the Document Processor

Use the following steps to prepare the document processor for installing the IM or dual IM:
WARNING
Shut off electrical power to the document processor before proceeding with installation. Injury may result from electrical shock. The document processor is hard-wired to the facility power supply. Power must be shut off from the facility circuit breaker panel. Check to be sure power has been shut off before proceeding.
1. 2. 3.
Remove the left-end, front, and rear panels from the document processor, and set them aside for later installation. Remove the quarter panel and lower mounting bracket (if present) from the right end of the basic unit. Set them aside for later installation on the IM or dual IM. Do one of the following: If the document processor is not already installed, skip to Installing the Imaging Module later in this section. If the document processor is installed, continue with step 4 for DP 1XXX units or step 5 for NDP 1XXX units to disconnect all mechanical and electrical connections between the pocket modules and the rest of the document processor. Refer to Figure 2-1. Note: Mark any cables that do not have labels to insure that the proper cable connections are made.
4.
For DL1/DL2 DP 1XXX field upgrades, do the following: a. Disconnect the DC inter-connect harness (three white wires) from the first, fifth, and ninth pocket module driver boards (if present) and pull the cable(s) back past the reject pocket into the basic unit. Access is from the rear of the machine. Refer to Figure 2-2.
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Figure 22. Document Processor Electrical Connections b. Disconnect the signal harness (multicolored ribbon cable) from the first, fifth, and ninth pocket module driver boards (if present), and pull the cable(s) back past the reject pocket into the basic unit. Disconnect the control module AC cable from the circuit breaker CBCM in Area 1, if present. Pull the cable into the first pocket module. Disconnect the AC and DC NIE harnesses, if present, (that run to the pocket module) from the NIE power supply terminal strip. See Table 2-1. Table 21. NIE Power Supply Connection
c. d.
Harness AC
Wire No. 1 and 8 2 and 9
ESTB No. ESTB1-A ESTB1-B ESTB2-A ESTB2-A ESTB2-C ESTB2-D ESTB2-E
DC
1 and 2 3 and 35 5 4. 35. 36 6
e.
Disconnect the AC control cables listed in Table 2-2 from the basic pocket module and pull them back past the reject pocket into the basic unit or into the pocket module, if applicable.
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Table 22. AC Control Cables
Cable Designation PICP1 from PICJ1 or MICJ1 PICP2 from PICJ2 or MICJ2 CABP1 from CABJ1 CAB8 from CABJ8 CABP9 from CABJ9
Plug Location Frame bottom Frame bottom AC control gate AC control gate AC control gate
f. 5.
Go to step 6 of this procedure.
For DL3 (NDP 1XXX) field upgrades, disconnect the following cables, depending on the option configuration. a. Disconnect the following cables from Area 1 and pull them down into the first pocket section: b. Disconnect the Area 3 DC cable from the DC distribution PCBA, if present. Disconnect the Area 4 DC cable from the DC distribution PCBA, if present. Disconnect the control module AC cable from the circuit breaker CBCM in Area 1, if present. Disconnect the Area 2 AC harness from the back of the AC distribution cable.
Disconnect the following cables from the first pocket module 4-pocket driver card and pull them back toward Area 1: Area 2 DC harness Area 2/3/4 interface harness
6. 7. 8.
Disconnect the braided ground jumper bolted between the stacker frame and the basic unit frame at the basic unit end. Remove the full pocket switch and bracket for the reject pocket and place in the pocket as the wires permit. Remove the black plastic roller support, the stacker floor, and the metal front wall (near the fascia plate) associated with the reject pocket. Set aside for later reassembly. If a microfilmer is present, loosen the idler pulley on the timing belt (underneath the Area 2 baseplate) that transfers drive to the microfilmer module. Remove the belt.
9.
10. Slice the foam strip along the bottom front and rear of the unit (along the floor) between the first pocket module and the basic unit. 11. Remove the nuts, lock washers, and shoulder bolts connecting the first pocket module to the basic unit. Note: On units with TDC microfilm, retain all washers and rubber bushings for later reassembly using the shorter shoulder bolts supplied with the IM.
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Installing the Imaging Module

Use the following procedure to install the Imaging Module. 1. 2. Position the pocket modules so there is approximately 57.8 centimeters (22.75 inches) between the basic unit and the pocket modules. Locate the EMI ground strip (a pliable 32-inch long strip of rubber covered with a fine wire mesh) supplied with the IM. Using a strip of masking tape at each end, attach the EMI ground strip to the bottom of the image frame, along the left side (as viewed from the front of the module). Be sure that the strip touches the area of dull, black, conductive paint. This strip must press against the basic unit frame when the modules are joined together. Slide the IM carefully into place adjacent to the basic unit. Adjust the IM leveling feet so that the image base plate bolt holes in the side flanges are vertically aligned with the corresponding holes in the basic unit. Locate the proper shoulder bolts (supplied with the IM) for connecting the IM to the basic unit. Refer to Figure 2-3 and Table 2-3.
3. 4. 5.
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Figure 23. Image Module Shoulder Bolt Connections 6. 7. Attach the IM loosely to the basic unit. Install the rear shoulder bolt first. Verify that the 24-inch long EMI ground strip is attached to the lower left end of the stacker frame. Slide the stacker module(s) into position next to the IM and attach the IM unit to the stacker module. Install the rear shoulder bolt first. Level the entire unit. Note: The entire unit must be leveled at this time, even if this is an upgrade to a previously installed unit. See Leveling the Machine, the next topic in this section.
8.
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Table 23. IM Shoulder Bolt Usage
To Connect To: Area 1 NIE TDC Microfilm Unisys Microfilm Area 2
Use Bolt P/N 2111 2925 2111 2933 2111 2933 1105 6520 2111 2933
Shoulder Length 1.75 1.50 1.50 1.00 1.50
Notes:
All bolts use 1256 7491 lock washer and 1256 5420 nut supplied. On units with TDC microfilm, use all washers and rubber bushings previously removed with the bolts referred to in Table 2-3.
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Leveling the Machine

After all the required modules have been positioned and loosely secured, perform the following procedure to level the modules. 1. 2. 3. 4. 5. 6. Install two alignment posts on the right-hand side of the right-hand baseplate assembly. Install two alignment posts on the left-hand side of the left-hand baseplate assembly. Remove the panel brackets at the left end of the Area 1 module, if present. Remove the ground strap at the front right end of the Area 1 module. Install four alignment posts on the Area 1 Module. Attach a string to the alignment posts between the left end of the Area 1 module and the right-hand baseplate assembly. Refer to Figure 2-4.
Figure 24. Bolting and Alignment of 8-Pocket Modules 7. To verify that there is enough adjustment of the feet to compensate for floor irregularities, adjust the left and right feet of the basic stacker module until the string touches the right Area 1 post and the left stacker posts. This is an approximation of machine level.
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8.
If very little adjustment is left on the stacker feet, you will need to reposition the Area 1 plane slightly by raising or lowering its feet and repeating Step 7. Otherwise, for long machine, the last pocket module might not be adjustable. Having estimated machine adjustability, install two leveling posts on each endorser, high speed encoder, microfilmer, and Imaging Module, if present. If the optional TDC microfilmer is present on an upgrade, there might be places for four posts. Install all four posts. Note: It is important that the string pass over the center of each post along the length of the machine. If this is not the case, movement of a module might be required. Slight repositioning of an end module or even an intermediate module creates large results in the centering of the posts and string.
9.
10. Using the four posts on the Area 1 baseplate as planes of reference, perform the following to each downstream module. a. b. c. d. e. Tighten the baseplate coupling bolts. Adjust the left module feet so they are off the ground. Adjust the right module feet so that the string, when pinched on that module's right most post, contacts all posts back to the left end of Area 1. See Figure 2-4. Adjust the left module feet to touch the floor and carry some of the module weight; verify that the level has not been disturbed. Tighten the locknuts on each foot. Note: If the optional TDC microfilmer is part of an upgrade, be sure the coupling hardware, including the blue rubber pads, are correctly installed. Do not overtighten and squash the blue rubber pads.
11. If more pocket modules need to be installed, leave all leveling posts installed and go to Section 2 of the NDP Servicing Guide: Hardware Installation, "Attaching 8-Pocket Modules, Step 2. 12. Tighten all the module coupling bolts/nuts. 13. Reinstall the ground strap removed in step 5 after the leveling operation is complete. 14. Tighten all of the locknuts on all of the leveling feet. 15. Do one of the following: If a microfilmer module is not present, skip to Drive Installation - No Microfilm found later in this section. If a microfilmer module is present, continue with Installing Microfilmer Drive Transfer Components, next.
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Installing Microfilmer Drive Transfer Components

To pass the drive through the IM to the microfilmer module, transfer pulleys must be assembled to the IM base plate. The necessary pulleys and belts are found in the microfilmer drive transfer kit. Refer to Figure 2-5 to install the kit.
I m age D ri ve Tow er Mi crof i l m D ri ve P ul l ey E xi st i ng P ul l ey and S pacer S pacer P ul l ey A ssem bl y wi t h K ey E xi st i ng N utand W asher B el t
B el t
I dl er A ssem bl y
E xi st i ng N utand W asher 57 6 4
Figure 25. Timing Belt Installation Do one of the following: For Unisys microfilmers, skip to Drive Installation - Unisys Microfilmer, later in this section. For TDC microfilmers, continue with Drive Installation - TDC Microfilmer, next. If there is no microfilm, go to Drive Installation - No Microfilmer, later in this section.
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Drive Installation - TDC Microfilmer

Use the following procedure to install the drive belt from the IM to the TDC microfilmer module: 1. 2. 3. 4. 5. Loosen the bottom lock nut, using a wrench on the flats at the bottom of the stacker drive shaft to prevent the shaft from rotating. Remove the nut, washer, and the timing pulley on the bottom of the shaft. Discard the timing pulley. Locate and install the 16-tooth timing pulley supplied with the IM on the bottom of the shaft. Install the washer and lock nut. Tighten the nut using a wrench on the flats of the shaft to prevent the shaft from rotating. Install the timing belt supplied with the image drive kit over the pulley on the bottom of the stacker drive shaft and the pulley on the bottom of the IM drive shaft. Tension the belt according to T&A 3304 2078 found in Appendix A of this guide, Special Engineering Instructions and Tests and Adjustments. Go to Microfilmer Air Hose Relocation, found later in this section for the IC 1000/ IC 1825 Imaging Module.
6.
Drive Installation - Unisys Microfilmer

Use the following procedure to install the drive belt from the IM to the TDC microfilmer module: 1. Install the timing belt (which was previously used to drive the microfilmer module) over the pulley on the bottom of the stacker drive shaft and the pulley on the bottom of the IM drive shaft. Tension the belt according to T&A 3304 2078 found in Appendix A, Special Engineering Instructions and Tests and Adjustments. Continue with Microfilmer Air Hose Relocation, next, for the IC 1000/IC 1825 Imaging Module.
2.
Microfilmer Air Hose Relocation

Use the following procedure to relocate the microfilmer air hose(s) section for the IC 1000/IC 1825 Imaging Module: 1. Locate the black hoses supplied in the microfilmer drive kit. To install these in the microfilmer module, refer to SEI 3304 5097 found in Appendix A, Special Engineering Instructions and Tests and Adjustments. For the IC 1000/IC 1825 Imaging Module, go to Reject Pocket Assembly, found later in this section. For the NDP 1000-4X/NDP 1825-4X Imaging Module, go to Cooling Change Installation For the NDP 1000-4X/NDP 1825-4X Imaging Module later in this section.
2.
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Drive Installation - No Microfilmer

Choose one of the following to install the drive pulley where no microfilmer is present: If there is no idler arm on the bottom of the stacker bearing housing, continue with Procedure A, next. If there is already an idler arm on the bottom of the stacker bearing housing, skip to Procedure B, found later in this subsection.
Procedure A
Use the following procedure to install a drive pulley where there is not an existing idler arm idler arm. Refer to Figure 2-6. 1. 2. 3. 4. 5. 6. 7. 8. Loosen the tension on the add-on pocket module (pockets 3 through 6) drive belt by swinging the idler away from the belt. Remove the belt. Loosen the tension on the drive input timing belt by moving the motor toward the bearing housing. Remove the belt. Remove the stretch poly-vee belt that drives the pocket augers. Loosen the bottom lock nut, using a wrench on the flats at the bottom of the stacker drive shaft to prevent the shaft from rotating. Remove the nut, the washer, and the spacer on the bottom of the shaft. Discard the spacer. Remove the three pulleys and one spacer and key. Keep all parts in the same sequence for later reassembly. Place the idler pulley and arm assembly supplied with the image drive kit on the bearing housing base and secure in place. Reassemble pulleys previously removed from the shaft, substituting the longer key provided in the image drive kit.
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Figure 26. Idler Arm and Pulley Installation 9. Locate and install the 16-tooth timing pulley supplied with the IM drive kit.
10. Install the washer and lock nut. Tighten the nut using a wrench on the flats of the shaft to prevent the shaft from rotating. 11. Install the poly-vee auger belt, using an adjacent module as a guide to get the proper twist on the belt. This determines the direction of rotation on the augers. 12. Install and tension the drive input belt from the motor according to the T&A found in the document processor T&A package. This requires positioning the motor. 13. Install and tension the add-on pocket module drive belt according to the T&A found in the document processor T&A package. 14. Install the timing belt supplied with the image drive kit over the pulley on the bottom of the stacker drive shaft and the pulley on the bottom of the IM drive shaft. Tension the belt according to T&A 3304 2078 found in Appendix A, Special Engineering Instructions and Tests and Adjustments. 15. For the IC 1000/IC 1825 Imaging Module, go to Reject Pocket Assembly, found later in this section. For the NDP 1000-4X/NDP 1825-4X Imaging Module, go to Cooling Change Installation For the NDP 1000-4X/NDP 1824-4X Imaging Module later in this section.
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Procedure B
Use the following procedure to install a drive pulley where there is an existing idler arm. Refer to Figure 2-6. 1. Locate the idler pulley and arm assembly supplied in the image drive kit. Remove the pulley and post from the arm. Mount the post and pulley to the arm on the bottom of the stacker bearing housing. Discard the extra arm. Loosen the bottom lock nut, using a wrench on the flats at the bottom of the stacker drive shaft to prevent the shaft from rotating. Remove the nut, washer, and the spacer on the bottom of the shaft. Discard the spacer. Locate the key supplied in the image drive kit. Remove the key from the remaining pulleys on the shaft and replace it with the longer key. Locate and install the 16-tooth timing pulley supplied with the IM. Install the washer and lock nut. Tighten the nut using a wrench on the flats of the shaft to prevent the shaft from rotating. Install the timing belt supplied with the image drive kit over the pulley on the bottom of the stacker drive shaft and the pulley on the bottom of the IM drive shaft. Tension the belt according to T&A 3304 2078 found in Appendix A, Special Engineering Instructions and Tests and Adjustments. Go to Reject Pocket Assembly later in this section for the IC 1000/IC 1825 Imaging Module. For the NDP 1000-4X/NDP 1825-4X Imaging Module, continue to the next procedure in this section, Cooling Change Installation For the NDP 1000-4X/ NDP 1825-4X Imaging Module.
2. 3. 4. 5. 6. 7.
8.
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Cooling Change Installation For the NDP 1000-4X/ NDP 1825-4X Imaging Module
For field upgrades, install the Unisys microfilmer, Area 1, and pocket module cooling changes if they are not already present. Parts required for these changes are included in the upgrade kit. If the Unisys microfilmer is present, the blower motor must have an adapter to divert some of its cooling air to blow onto the motor itself. Rearrange the hoses and attach the air flow diversion adapter and restrictor as directed in the following steps: 1. 2. Remove the air outlet hose completely from its current location along the floor of the module. Starting from the rear of the camera unit, rest the hose along the top of the steel bracket. Wrap the hose under the steel bracket between the middle two frame side supports. Thread a plastic tie wrap through the front-most drill hole in the steel bracket, and secure the hose with the tie wrap. Refer to Figures 2-7 and 2-8 for two different views of the hose.
Figure 27. Relocating the Air Outlet Hose (Inside Module Looking Out)
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Figure 28. Relocating the Air Outlet Hose (Outside Module Looking In) 3. Referring to Figure 2-9, attach the air flow diversion adapter onto the air flow outlet (where the outlet hose was previously attached). Position the adapter so that the two holes face the blower motor (refer to dashed circles in Figure 2-9). Mount the restrictor between the airflow diversion adapter and the output hose adapter, and secure the outlet hose onto the adapter. Tighten both clamps to hold the adapter and hose in place.
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Legend
1 2 3 4 5 Blower motor Output hose Output hose adapter Restrictor Air flowdiversion adapter
Figure 29. Detail of Air Flow Diversion Adapter Location 4. Relocate the input hose to the front right side of the Imaging Module on the bottom. Cut the hose to length and secure it in place on the output bracket with the clamp that is provided. For the first 8-pocket module, make the cooling modification according to the following steps: a. b. Install the fan panel assembly with three fans to the middle frame members below pocket 2. Use the screws and washers provided. Mount the bracket with the single fan to the back frame member below the reject pocket so that it blows air directly at the transport motor. Use the screws and washers provided. Connect the 3-fan harness together.
5.
c.
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d.
On NDP units, connect all four fans and plug the 4-pin plug into connector A2FAN on the motor capacitor plate. For DP units, connect it to CABP5 on the AC control cage.
6.
For the Area 1 AA gate, on NDP units only, add a baffle to direct air onto the top power supply just like the lower power supply as follows: a. b. c. d. Using the baffle as a template, mark the location of two holes 5.57 inches from the bottom of the gate. Tape a protective cover or cloth over the power supplies to prevent metal shavings from getting into them. Drill two 0.200-inch holes. Mount the baffle using the hardware provided.
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Reject Pocket Assembly

Use the following procedure to install the reject pocket assembly: 1. 2. Install the black plastic roller support on the image and stacker base plates. Position the flag so its roller runs in the track of the roller support. Install the full pocket switch and bracket (previously removed) to the image base plate. Verify that the pocket flag moves along the path of its travel without any resistance. Install the stacker floor. Install the steel pocket front wall. Connect the almost full pocket switch wires for the NDP units, first. Verify that the flag movement is not impeded. Attach the flat trim wall shipped on the Area 1 hopper brackets to the image base plate, using the two L-shaped brackets also shipped with the Area 1 module. Notes: 1. The flat trim wall may already be mounted in an NIE or microfilmer module. If so, it should be transferred to the IM. 2. A Unisys microfilmer module requires a special trim wall which is shipped with the microfilmer module. This trim wall should be removed from the microfilmer module and is not to be used in the IM unless the flat wall is no longer present in the basic unit. 6. Attach the curved filler plate shipped with the stacker module to the reject pocket roller support and to the trim wall to fill the gap between the two parts. Note: This filler plate may already be installed in a previous module and should be moved to the IM.
3. 4. 5.
7.
Locate the quarter panel previously removed from the basic unit. The foam around the louvers needs to be modified to match the image fan. Remove the foam as shown in Figure 2-10.
Figure 210. Quarter Panel Foam Removal
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8. 9.
Bolt the quarter panel hanger bracket (if previously removed from the basic unit) to the IM frame with the notches up. Continue with Top Cover Trim Installation, next.
Top Cover Trim Installation

The trim plate on the top cover of the basic unit must be changed. The plate to be changed was previously located beside the reject pocket. A different trim plate is installed depending on the machine configuration. Follow the instructions for the module associated with the basic unit.
Area 1
Use the following procedure to install the trim piece in a basic unit that is an Area 1 module: 1. Remove the L-shaped stainless trim and the formed trim cap from underneath the square bar on the top cover by loosening the necessary hardware from underneath the cover. Locate the rectangular trim plate (5 1/2 x 12 1/2) supplied with the IM. Fit it to the hole pattern in the top cover. Align with adjacent trim plate(s). Secure from below using the hardware previously removed. Secure the square bar. Loosen the screws securing the square bar on the top cover of the IM. Install the formed trim cap (removed from the basic unit) to the hole pattern in the cover. Align it with the adjacent plate(s). Secure with hardware previously removed. Secure the square bar. Skip to Installing Document Processor Interface Harnesses and Logic, found later in this section.
2.
3.
4.
NIE/MJE
Use the following procedure to install the trim piece in a basic unit that is an NIE or MJE module: 1. Remove the stainless trim and the formed trim cap (located to the right of the hopper) from underneath the square bar on the top cover by loosening the necessary hardware from underneath the cover. Locate the rectangular trim plate (22 3/4 x 12 1/2) supplied with the IM. Fit it to the hole pattern in the top cover. Align it with the adjacent trim plate(s). Secure from below using the hardware previously removed. Secure the square bar. Loosen the screws securing the square bar on the top cover of the IM. Install the formed trim cap (removed from the basic unit) to the hole pattern in the cover. Align with adjacent plate(s). Secure with hardware previously removed. Secure the square bar. Skip to Installing Document Processor Interface Harnesses and Logic, found later in this section.
2.
3.
4.
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High Speed Encoder Module

If the NDP 1XXX basic unit ends with a High Speed Encoder Module, a new trim piece is required. Order the 30-inch rectangular trim piece specified in the NDP Servicing Guide: Parts Catalog.
Unisys Microfilmer
Use the following procedure to install the trim piece in a basic unit that is a Unisys microfilmer module: 1. Remove the formed trim cap and the stainless trim (toward the front of the cover) from underneath the square bar on the top cover by loosening the necessary hardware from underneath the cover. Note: On some older units, the rear trim plate and formed trim cap are all one piece.
2.
Locate the rectangular trim plate (22 x 12 1/2) supplied with the IM. Fit it to the hole pattern in the top cover to the front of the square bar. Align it with the adjacent trim plate(s). Secure from below, using the hardware previously removed. Loosen the screws securing the square bar on the top cover of the IM. On machines where the trim cap was previously removed from the microfilmer module was a part of the rear trim plate, remove the rear trim plate from the IM top cover, and install it on the microfilmer top cover. Install the large trim plate with attached trim cap (removed from the microfilmer unit) to the hole pattern in the IM cover. Align it with the adjacent plate(s). Secure with hardware previously removed. Secure the square bar on the IM and microfilmer. Otherwise, install the formed trim cap (removed from the microfilmer) to the hole pattern in the IM cover. Skip to Installing Document Processor Interface Harnesses and Logic, found later in this section.
3.
4.
TDC Microfilmer
Use the following procedure to install the trim piece in a basic unit that is a TDC microfilmer module: 1. Three holes need to be added to the microfilmer top cover to secure the trim plate to that cover. Refer to SEI 3304 4827 found in Appendix A, Special Engineering Instructions and Tests and Adjustments. Locate the rectangular trim plate (3 1/8 x 22 1/2) supplied with the IM. Fit it to the hole pattern in the top cover. Align it with the adjacent trim plate(s). Secure from below, using the hardware provided with the IM upgrade kit. Loosen the screws securing the square bar on the top cover of the IM. Locate the formed trim cap supplied with the IM upgrade kit. Install the formed trim cap to the hole pattern in the cover. Align with adjacent plate(s). Secure with hardware provided. Secure the square bar. Continue with Installing Document Processor Interface Harnesses and Logic, next.
2.
3.
4.
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Installing Document Processor Interface Harnesses and Logic With an IC 1000/IC 1825 Imaging Module
WARNING
Shut off the electrical power to the document processor before proceeding with installation. You must check to be sure power has been shut off before proceeding. Injury may result from electrical shock. The document processor is hard-wired to the facility power supply. Power must be shut off from the facility circuit breaker panel.
Use the following procedure to install the document processor interface harnesses and logic: 1. Remove the BOL/interlock harness coiled in the bottom of the IM frame. Locate the two small black plastic backplane jumpers attached to the cable. These are to be applied to the document processor backplane to locate the image BOL/interlock harness for DL1 document processors only. Install one of the jumpers at card slot 4 AA4J2 pins 9 and 10 and the other at AA4J2 pins 71 and 72. Uncoil the BOL/interlock harness, and route it along the bottom of the frame back to the basic unit logic gate, going under the microfilmer and NIE hardware (if present). For DL1 units, connect the J2 plug end of the harness to the backplane on card slot 4, AA4J2 (between the jumpers). The letter A molded in the connector housing designates the corner pin that is to be connected to pin 12 on the backplane. For DL2 document processors, install the cable at AAJ13. For DL3 document processors, place the cable in the input side of the previous module (if one exists). If not, install the cable at AAJ4. Lay the harness and any extra length in the Area 1 cable tray. Refer to Figure 2-11.
2. 3.
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Figure 211. BOL/Interlock Harness Installation 4. 5. 6. 7. Install the Image Interface PCBA into slot 15 of the basic unit AA logic gate for IC 1000/IC 1825 units. Remove the front panel of the circuit breaker box in the Area 1 module at the rear of the machine. Measure the voltage across the two top lugs on the basic unit circuit breaker (CBBU). If the voltage is not zero, do not proceed until power is removed from the line. Locate the 30-amp circuit breaker supplied with the IM. Remove the cover plate, and install the image circuit breaker on the panel in the space provided at the upper left corner. Refer to the wiring instruction in Figure 2-12 for the proper connections to the circuit breaker. The jumpers referred to are provided.
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Figure 212. Breaker Panel Wiring
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8.
Locate and install the image RFI line filter in the breaker housing, beside the sorter filter. Refer to wiring instruction in Figure 2-13 for the proper connections to the filter. The jumpers referred to are provided.
Figure 213. Image RFI Filter 9. Attach the AC input cable to the image circuit breaker, using the following procedure: a. b. c. d. Locate the AC input cable coiled in the bottom of the IM. Run this cable back to the Area 1 circuit breaker housing. Insert the cable through the strain relief clamp in the bottom of the circuit breaker panel. Connect the cable to the two bottom terminals of the image circuit breaker as shown in Figure 2-13. Secure the strain relief clamp on the cable.
10. Close the circuit breaker cover, and secure with the hardware previously removed. 11. Locate, route, and reconnect all of the cables previously removed in Preparing the Document Processor, found earlier in this section. 12. Install the image button light, using the following procedure: a. b. Remove the blank indicator lens from the fourth position to the right of the red Power On switch on the document processor operator control panel. Locate the indicator lens supplied with the IM. Insert a lamp into the Image On lens and snap it into the fourth switch position.
13. Check the part numbers on the PCBAs and PROMs in the document processor AA logic gate, using Table 2-4. Those components listed must be at the specified level or higher to operate correctly with the Imaging Module installed.
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Table 24. PROM and PCBA Minimum Levels
Card Location Slot 1 Slot 2 Slot 4 Slot 8 Slot 17
Minimum Level (DL1 and DL2) 4142 7568-001 or 4142 8236-001 4142 9515-002 4142 9523-002 4142 9614-002 PROMS at location AH30 and AP30 must be at level 3.0.0 or higher.
Minimum Level (DL3) Not applicable (NA) 4327 7854-004 NA 4327 7821-007 or 2493 5561-008 NA-
14. Check Table 2-5 to ensure that the wires listed have been added to the AA gate backplane prior to running the transport with the image track added. Table 25. Added AA Gate Backplane Wiring
Signal Name IMAGEPL/ READCLR/
From 4J1-52 10J1-59
To 4J1-98 15J1-59
15. For a DP 18XX, verify that the customer has installed a 75-ampere circuit breaker on the line feeding power to the document processor (check for a 60-ampere circuit for a DP 1000 or NDP 1XXX unit). Note: If the configuration of the document processor is greater than sixteen pockets, refer to SEI 2494 6436 found in Appendix A, Special Engineering Instructions and Tests and Adjustments, for an explanation on motor/load redistribution.
16. Verify that the jumpers on cards 1, 2, and 4 of the document processor AA logic gate relate to machine configuration and Area 2/3 motor belting. Refer to the instructions on schematic sheet 09.01.01 accompanying the upgrade kit. 17. Do one of the following: Install the IM electronics gate, skip to Unpacking the U4 or JPEG Electronics Gate and CCITT Gate, found later in this section. Stop imaging installation to allow the customer to use the document processor: Refer to the DP 1825 Installation Guide, Section 2, Installation, and perform
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the pre-power on and power on checks. Verify that all breakers are reset. Install all the panels on the document processor and the IM.
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Installing Document Processor Interface Harnesses and Logic With an NDP 1000-4X/NDP 1825-4X Imaging Module
WARNING
Use the following procedure to install the document processor interface harnesses and logic: 1. Remove the BOL/interlock harness coiled in the bottom of the IM frame. Locate the two small black plastic backplane jumpers attached to the cable. These are to be applied to the document processor backplane to locate the image BOL/interlock harness. For DL1 document processors only, install one of the jumpers at card slot 4 AA4J2 pins 9 and 10 and the other at AA4J2 pins 71 and 72. For DL1 units, connect the J2 plug end of the harness to the backplane on card slot 4, AA4J2 (between the jumpers). The letter A molded in the connector housing designates the corner pin that is to be connected to pin 12 on the backplane. For DL2 document processors, install the cable at AAJ13. For DL3 document processors, place the cable in the input side of the previous module (if one exists). If not, install the cable at AAJ4. Lay the harness and any extra length in the Area 1 cable tray. Refer to Figure 2-14.
2.
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Figure 214. BOL/Interlock Harness Installation 3. 4. 5. Install the Dual MIIB PCBA into slot 3 of the basic unit AA logic gate. Locate, route, and reconnect all of the cables previously removed in Preparing the Document Processor, found earlier in this section. Install the image button light, using the following procedure: a. b. 6. Remove the blank indicator lens from the fourth position to the right of the red Power On switch on the document processor operator control panel. Locate the indicator lens supplied with the IM. Insert a lamp into the Image On lens and snap it into the fourth switch position.
Install the dual MIIB interface harness from the dual image backplane connector JX513 to the AA gate card 3 connector P3. Route the cable through the bottom frame holes that are farthest back, up the left side of the AA gate, over the top, and into connector AA03-P3. Connect logic ground from the dual IM to DC1B7 (for an NDP document processor) or TB2A14 for a DL1 or DL2 machine.
7.
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8.
For DL1/DL2 units, add the appropriate wires listed in Table 2-6. Table 26. Added AA Gate Backplane Wiring Changes For Dual IM DL1/DL2 Units
Action Cut Cut Add Add Add Add Add Add
Signal Name FEED/ FEED/ FEED/ IMAGEON/ BOLI1/ IMNRDY/ MTWE/ SP0INT/
From 2J1-53 3J1-53 2J1-53 3J1-20 3J1-53 3J2-14 3J2-19 3J2-87
To 3J1-53 8J1-53 8J1-53 1J1-18 4J1-53 8J2-14 2J2-19 8J2-87
Required For DL1 only DL1 only DL1 only DL1, DL2 DL1, DL2 DL1, DL2 DL1, DL2 DL1, DL2
9.
Add the following 12 wires shown in Table 2-7 for DL3 units with 4142 9770-001 AA gate artwork (if not already installed), or the wires shown in Table 2-8. Table 27. Added AA Gate Backplane Wiring Changes For Dual IM DL3 Units
Action Add Add Add Add Add Add Add Add Add Add Add Add
Signal Name IMAGEON/ BOLI1/ TNENBL/ IMNRDY/ MTWE/ TN1N/ TN2N/ TN4N/ TN8N/ TN16N/ SP0INT/ TN32/
From 3J1-20 3J1-53 3J1-57 3J2-14 3J2-19 3J2-70 3J2-72 3J2-80 3J2-81 3J2-82 3J2-87 3J2-89
To 8J1-30 2J1-49 2J1-57 8J2-13 2J2-19 2J2-72 2J2-73 2J2-75 2J2-81 2J2-83 8J2-69 2J2-85
Add the following wire shown in Table 2-8 for DL3 units with 4142 9770-002 AA gate artwork (if not already installed).
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Table 28. Added AA Gate Backplane Wiring Changes For Dual IM DL3 Units
Action Add
Signal Name MTWE/
From 3J2-19
To 3J2-18
10. Check the part numbers on the PCBAs and PROMs in the document processor AA logic gate, using Table 2-9. Those components listed must be at the specified level or higher to operate correctly with the Imaging Module installed. Table 29. PROM and PCBA Minimum Levels
Card Location Slot 1 Slot 2 Slot 4 Slot 8 Slot 17
Minimum Level DL1/DL2 4142 7568-001 or 4142 8236-001 4142 9515-002 4142 9523-002 4142 9614-002 PROMS at location AH30 and AP30 must be at level 3.0.0 or higher.
Minimum Level DL3 Not applicable (NA) 4327 7854-004 NA 4327 7821-003 or 2493 5561-008 NA
11. Verify that the customer has installed a 75-ampere circuit breaker on the line feeding power to the document processor for DP 18XX units, and a 60-ampere breaker for all other units. Note: If the configuration of the document processor is greater than sixteen pockets, refer to SEI 2494 6436 found in Appendix A, Special Engineering Instructions and Tests and Adjustments, for an explanation on motor/load redistribution.
12. Verify that the jumpers on cards 1, 2, and 4 of the document processor AA logic gate relate to machine configuration and Area 2/3 motor belting. Refer to the instructions on schematic sheet 09.01.01 accompanying the upgrade kit.
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13. Do one of the following: Continue to the next procedure in this section, Circuit Breaker Installation on a Dual Imaging Module. Stop imaging installation to allow the customer to use the document processor. Refer to the NDP Servicing Guide: Hardware Installation Section 2, Installation, and perform the pre-power on and power on checks. Verify that all breakers are reset. Install all the panels on the document processor and the IM.
Circuit Breaker Installation on a Dual Imaging Module

WARNING
Use the following procedure to install the circuit breaker. 1. 2. Remove the front panel of the circuit breaker box in the Area 1 module at the rear of the machine. Locate the 10-amp circuit breaker supplied with the dual IM. Remove the cover plate, and install the image circuit breaker on the panel in the space provided at the upper left corner. Refer to the wiring instruction in Figure 2-15 for the proper connections to the circuit breaker. The jumpers referred to are provided.
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Figure 215. Breaker Panel Wiring
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3.
Attach the AC input cable to the image circuit breaker, using the following procedure: a. b. c. d. Locate the AC input cable coiled in the bottom of the dual IM. Run this cable back to the Area 1 circuit breaker housing. Insert the cable through the strain relief clamp in the bottom of the circuit breaker panel. Connect the cable to the two bottom terminals of the image circuit breaker. Secure the strain relief clamp on the cable.
4.
Apply power to the image circuit breaker using the jumper harness supplied with the dual IM. a. b. For all NDP units, install one of the jumpers at pin CBBUA01 to image A0. Install the other jumper in CBBUB01 to image B0. For DL1/DL2 units, locate the image RFI line filter in the breaker housing, beside the sorter filter. Refer to the wiring instruction for Figure 2-16 for the proper connection to the filter. The jumpers referred to are provided.
5.
Close the circuit breaker cover, and secure it with the hardware previously removed.
Figure 216. Image RFI Filter 6. Go to Installing Dual Imaging Module Interface Cables later in this section.
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Unpacking the U4 or JPEG Electronics Gate and CCITT Gate

Under some conditions with a new machine installation, the U4 electronics gate may ship installed inside the pocket module. If this is true for the U4 electronics gate, skip to Installing the U4 Electronics Gate PCBAs later in this section; otherwise, use the following procedures to unpack the U4 or JPEG electronics gate:
U4 Electronics Gate
Perform the following procedure to unpack the U4 electronics gate: 1. 2. 3. 4. Cut the straps around the outside of the pallet. Locate the box that contains the electronics gate frame and remove the electronics gate frame from the box. Inspect the unit and record any damage found in a log book. Remove the front and rear EMI covers by loosening the thumbscrews and pulling each cover straight out.
Caution
You must use a wrist strap when removing and replacing a PCBA. Failure to use a wrist strap could result in equipment damage from each electrostatic discharge.
5. 6.
Remove all PCBAs (if present) from the electronics gate. Refer to PCBAs in Section 4, Maintaining the IC 1000/IC 1825 Imaging Module. Remove the fan filter from the plenum assembly by using the following procedure. Refer to Figure 2-17. a. b. c. Remove the two hex nuts securing the retaining clips to the plenum. Remove the retaining clips. Remove the filter by pulling the top edge forward and lifting it up.
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Figure 217. Electronics Gate and Plenum 7. Perform the following steps to remove the electronics gate from the plenum assembly: a. b. c. 8. Remove the four hex head screws securing the electronics gate to the plenum. Lift the electronics gate from the plenum. Lift the lower EMI shield from the plenum.
Continue with Installing the U4 Electronics Gate, next.
JPEG Electronics Gate

Use the following procedure to unpack the JPEG electronics gate: 1. 2. 3. 4. Cut the straps around the outside of the pallet, and remove all exterior packing materials. Locate the main electronics gate, and remove it from the pallet. Remove the front and rear gate covers by loosening the thumbscrews and pulling each cover straight out. Inspect the gate, inside and out, and record any damage found.
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Installing the U4 Electronics Gate

The U4 electronics gate is installed under the base plate of the right half of the first pocket module (pockets 3 through 6). The electronics gate is shipped with the parts necessary to install it in an eight-pocket module. Document processors with four-pocket modules must be upgraded to eight-pocket modules before this installation. Refer to SEI 4139 5260. Use the following procedure to install the U4 electronics gate in a document processor configured with eight-pocket modules. Locate the kit of parts shipped with the electronics gate. The major elements of the kit are two flat plates with fan openings, an offset bracket for mounting a power supply, and two rails for supporting the electronics gate. Note: Refer to "Installing the JPEG and CCITT Electronics Gate," later in this section, for procedures to install a JPEG electronics gate.
Perform the following procedure to install the U4 electronics gate: 1. Remove the front and rear panels from the IM and the first two eight-pocket modules (if they are on the machine). Remove the right end panel from the stacker module if the machine ends at the eighth pocket. Locate the two electronics gate mounting rails (24.87 inches long) in the electronics gate kit. These rails are not symmetrical. The end of each rail with a clinch nut 3.31 inches from the end is to be located toward the front of the pocket module. Position the rails in the bottom of the frame, below the second base plate, roughly in line with the tapped holes on the flanges of the frame. Refer to Figure 2-18.
2.
Figure 218. Electronics Gate Mounting Rails
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3. 4.
Clamp the rails in place with the four L-shaped brackets and 1/4-20 bolts provided. Be sure the bracket tabs engage the slots in the rails. Tighten all bolts. Remove the fan panel located on the center frame members, using the following procedure: a. b. Remove the fan cables from the fans by pulling on the insulated connectors. Remove the four screws securing the panel to the frame. Remove the panel from the pocket module.
5.
Remove the pocket driver board from the pocket module, using the following procedure: a. b. Disconnect the three harnesses from the top edge of the board. Disconnect the white voltage and ground cables (coming from the previous module and going to the next module) from the tabs along the bottom of the board. Disconnect the ribbon cables from each end of the board. Remove the four screws securing the board mounting brackets to the base plate. Set aside for later use.
c. d. 6. 7. 8. 9.
Place the plenum into the pocket module on the rails with the fans toward the rear of the machine. Position the plenum over the set of clinch nuts in the support rails that locate the assembly toward the front of the machine. See Figure 2-18. Secure the rear of the plenum to the rails, using two 1/4-20 bolts provided. Secure the brackets at the front of the plenum to the rails, using two 1/4 2D20 bolts. Tighten all hardware. If the holes do not all line up well enough to allow the screws to be started, the rails or the front plenum bracket may need to be realigned.
10. Place the lower EMI shield on top of the plenum. Align the screw holes. 11. Place the electronics gate on top of the plenum with the backplane toward the front of the machine. Secure to the plenum, using the screws previously removed. 12. Insert the bottom edge of the filter (previously removed) into the channel at the rear of the plenum and fit into the opening. Install the retaining clips and secure with the hex nuts. 13. Choose one of the following, depending on whether or not the fan panel previously removed from the center frame member has a 3.5 inch x 1.44 inch rectangular opening beneath the bottom rear fan. If the fan panel has the opening, perform the following procedure. Refer to Figure 2-19. a. b. c. Remove the two hex nuts and screws securing the fans to the Remove the flat metal cover plate attached to the panel. Locate the wireform fan guards supplied with the electronics gate kit.
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d.
Secure the two fans to the panel (on the side that will be opposite the electronics gate) at the openings that are aligned one above the other, with the direction of air flow (note arrow on fan housing) toward the electronics gate and a fan guard between the plate and each fan. Refer to Figure 2-19.
Figure 219. Center Frame Fan Panel e. Insert the panel into the stacker module on the opposite side of the center frame members from the electronics gate. Secure to the frame, using the hardware previously removed. Connect the fan cables to the terminals on the two fans.
f.
If the fan panel does not have the opening, perform the following procedure. Refer to Figure 2-19. a. b. Remove the two hex nuts and screws securing each fan to the panel. Remove the fans. Locate the fan panel (containing the rectangular cutout) supplied with the upgrade kit. This panel mounts in the same orientation as the panel previously removed. Locate two wireform fan guards also supplied with the IM electronics gate.
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c.
Secure the two fans to the panel (on the side that will be opposite the electronics gate) at the openings that are aligned one above the other, with the direction of air flow (note arrow on fan housing) toward the electronics gate and a fan guard between the plate and each fan. Refer to Figure 2-19. Insert the panel into the stacker module on the opposite side of the center frame members from the electronics gate. Secure to the frame, using the hardware previously removed. Connect the fan cables to the terminals on the two fans.
d.
e.
14. Locate a panel (supplied with the electronics gate) with three fan openings and two rectangular notches at the bottom. Locate three fans, wireform fan guards, and hardware supplied with the electronics gate. 15. Perform one of the following: If the document processor does not end at the eighth pocket, perform the following procedure. Refer to Figure 2-20.
Figure 220. Fan Panel a. Slide the panel between the two adjacent eight-pocket frames, using the hardware provided.
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b.
Secure the one front fan to the panel (on the same side as the electronics gate) with the direction of air flow (note arrow on fan housing) away from the electronics gate. Install a fan guard on the electronics gate side of the fan. Refer to Figure 2-20. Secure the two remaining fans to the panel (on the side opposite the electronics gate), with the direction of air flow (note arrow on fan housing) away from the electronics gate and a fan guard between the plate and each fan. Refer to Figure 2-20.
c. d.
If the document processor ends at the eighth pocket, perform the following procedure. a. Secure the three fans to the panel (on the side that will be facing the electronics gate), with the direction of air flow (note arrow on fan housing) away from the electronics gate. Install a fan guard on the electronics gate side of each fan. Refer to Figure 2-21.
b.
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Figure 221. 5-Volt Power Supply c. Position the panel against the end of the stacker module, aligned with the hole pattern on the frame. Secure to the frame, using the hardware previously removed. Locate the new end panel kit supplied with the upgrade kit. This panel is identical in size to the old end panel but has louvers to allow for the fan exhaust. Swap all hardware required from the old panel to the new panel, and mount the new panel in the pocket module.
d.
16. Locate the fan jumper harness supplied with the electronics gate kit. Connect the two fan harness to the terminals of the rear fans and route the harness toward the front of the machine. 17. Connect the one fan harness to the terminals of the front fan. 18. Place the harness in the bottom of the stacker module at the front of the electronics gate back toward the basic unit.
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19. Feed the rest of the harness through the opening in the side of the frame and underneath the AC control gate. 20. Remove the plastic cover from the AC control gate located in the bottom of the stacker module. 21. Disconnect the fan harness from location CAB-6. Carefully pull the plug end of the jumper harness up through the plate and plug it into the AC control backplane at location CAB-6. This may require lifting the equipment plate for better access. 22. Plug the connector of the two fan harnesses removed in step 20 into the plug on the jumper harness. Carefully feed the excess wire under the plate. 23. Locate the offset bracket and the 5-volt power supply shipped with the electronics gate kit. Mount the supply to the bracket, using the hardware supplied. Refer to Figure 2-22 for proper orientation of the supply on the bracket. 24. Position the bracket and supply on the plate in the bottom of the stacker module containing the AC control gate, with the terminals of the supply toward the front of the machine. Secure with the hardware supplied. 25. Position the bracket and supply on the plate in the bottom of the stacker module containing the AC control gate, with the terminals of the supply toward the front of the machine. Secure with the hardware supplied. 26. Drill two holes in the rear of the pocket module frame for attaching a cable restraint bracket to the frame. See Figure 2-22 for the location of the two 0.281 diameter holes.
Figure 222. Frame Drilling Locations 27. Locate the cable restraint bracket shipped with the IM. Position it on the inside of the stacker frame, inserting the 1/2-inch 1/4-20 bolts supplied from the outside of the frame. Install and tighten the nuts provided.
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28. Replace the pocket driver board (previously removed), using the following procedure: a. b. c. Line up the two brackets with the holes in the base plate, and secure with the four screws. Connect the ribbon cables from the adjoining modules to each end of the board. Ensure the latches engage the connector. Connect the white voltage and ground cables from the adjoining modules to the proper tabs along the bottom of the board. Look at the adjoining boards for an example. Connect the three harnesses to the connectors along the top edge of the board.
d.
29. Locate the 5-volt power supply EMI housing shipped with the unit. Fit the housing over the power supply, and attach it to the power supply bracket, using the hardware provided. 30. Continue with "Installing the U4 Electronics Gate PCBAs," next in this section.
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Installing the U4 Electronics Gate PCBAs

Use the following procedure to install the PCBAs in the U4 electronics gate: 1. Locate the image logic boards previously removed from the gate or packed in their individual shipping boxes. Refer to "PCBAs" in Section 4, "Maintaining the IC 1000/IC 1825 Imaging Module," for proper handling of the logic boards. Refer to Table 2-11 for PCBA locations. Card locations are marked on the gate. Table 211. U4 Electronics Gate PCBA Locations
Slot Location 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
PCBA Description Image digitizer Resequencer Image processor Image processor Reserved Image processor Image processor Transposer/compressor Transposer/compressor Transposer/compressor Transposer/compressor Compressed data buffer Main processor Reserved POL controller Reserved DTI Compressed data buffer Transposer/compressor Transposer/compressor Transposer/compressor Transposer/compressor Image processor Image processor Reserved for CAR
continued
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Table 211. U4 Electronics Gate PCBA Locations (cont.)
Slot Location 25 26 27 28
PCBA Description Image processor Image processor Resequencer Image digitizer
2. 3.
Connect the internal DTI cable to J1 of the DTI PCBA. Connect the internal POL cable leads to the jacks located on the POL PCBA. Refer to Table 2-12. Table 212. POL Cable Connections
Harness Designation A B
Jack Designation XMT RCV
4. 5.
Install the rear EMI cover. Continue with "Connecting the U4 Image Cables," next in this section.
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Connecting the U4 Image Cables

Carefully extend the cables coiled in the bottom of the IM out the rear of the unit. As these are identified they can be routed in the proper direction for installation. Use the corresponding procedure for each cable. For further information on cable connections, refer to the cables and harnesses tables found in Section 4, "Maintaining the IC 1000/ IC 1825 Imaging Module." After installing all the cables, continue with "U4 and JPEG IM Power Up and Checkout," later in this section.
Secondary AC Harness
Use the following procedure to connect the secondary AC harness. The secondary AC harness is the insulated wire connected to the IM circuit breaker housing, the 15-volt power supply, and the lamp power supply. The coiled end should be routed into the stacker module, at the rear of the center vertical member of the stacker frame. 1. 2. 3. 4. Feed the end of the cable under the equipment panel in the bottom of the stacker module, toward the front of the machine. Feed the cable up through the rectangular hole in the equipment plate toward the terminals on the 5-volt power supply. Connect the leads of the cable to the power supply. Refer to Figure 2-23. Coil the extra length of the cable under the equipment plate.
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Figure 223. Secondary AC Harness Routing
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IM Fan Harness
Use the following procedure to connect the IM fan harness. Refer to Figure 2-24. The fan harness feeds power to the energy dump fan, the lamp fan, and the module fan mounted to the frame. The installed end of the harness is tied to the right hand slide support. The coiled end should be fed into the stacker module and under the equipment plate.
Figure 224. IM Fan Harness Routing 1. 2. 3. 4. Feed the AC connector up to the AC control gate through the rectangular hole in the equipment plate. The equipment plate may need to be raised for best access. Unplug the fan connector from the plug at backplane designation CAB-7. Plug the image fan harness into that plug (CAB-7). Plug the connector previously removed from CAB-7 of the backplane into the connector of the image fan harness. Do one of the following: For U4 only, run the last leg of the image fan harness over to the electronics gate. Plug the connector into the gate fan harness at the side of the plenum through the rectangular opening in the fan panel. Go to Step 5 of this procedure. For JPEG only, cover the open end of the connector on the last leg of the image fan harness with electrical tape. Coil this unused harness leg and secure it under the equipment plate, taking care to keep wiring out of the CAB's bottom fan.
5. 6. 7.
Secure the ground wire to the post on the plenum with the hardware supplied. Coil the extra length under the equipment plate. Locate the new plastic AC control cover supplied with the upgrade kit. It looks like the old one, but it has an additional cutout at the bottom for the extra cables. Secure the cover to the AC control gate.
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24-Volt Bias Harness

Use the following procedure to connect the 24-volt bias harness. The 24-volt harness is wired into the image circuit breaker panel at the rear of the module. Feed the free end of the harness through the basic unit, passing under the hardware and sub-modules in the bottom of the frames. 1. Run the harness through the cable tray along the bottom of the AA logic gate, exiting the tray near the 24-volt and ground studs on the AA backplane. Secure the leads to the backplane. Refer to Figure 2-25.
Figure 225. 24-Volt Bias Harness Routing 2. Place the extra length of the cable in the cable tray located in the bottom of the basic unit frame.
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Document Processor Interface Cable

Use the following procedure to connect the document processor interface cable. The cable is coiled and included in the installation kit. Refer to Figure 2-26. 1. 2. Locate the end of the cable with the plastic end shroud attached to it. Remove the shroud. Locate the unused fan opening in the fan plate (front side). Route the cable through the empty fan opening.
Figure 226. Document Processor Interface Cable Routing 3. 4. Pass the cable over the equipment panel and toward the rear of the machine. Route the cable along the rear of the machine toward the basic unit frame.
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5. 6. 7. 8.
Lay the cable into the cable trays under the AA gate. Allow a sufficient service loop between the cable trays to allow the gate to swing open without pulling on the cable. Place the shroud on the pins at AAJ12 of the AA backplane. Plug the cable into the AA backplane at AAJ12. Plug P15 into the gate shroud at the electronics gate, and secure with the thumb screws.
Five-Volt Power Supply Ground Cable

Use the following procedure to connect the 5-volt power supply ground cable. The cable connects between the "-" terminal on the face of the 5-volt power supply and the terminal TB2-14 on the center post in the basic unit frame. Refer to Figure 2-27. 1. Route the wire from the basic unit toward the stacker module, passing under the submodules in the NIE and microfilmer (if present). Follow the path of the secondary AC harness to the 5-volt power supply. Connect and restrain the ends as shown in Figure 2-27.
2.
Figure 227. 5-Volt Power Supply Ground Cable Connection
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Five-Volt DC Sense Harness

Use the following procedure to connect the 5-volt DC sense harness. The harness connects between the power control harness (coming from the 15-volt power supply and the image circuit breaker housing), the 5-volt power supply, and the image backplane. The power control harness is coiled in the IM and terminates with one connector. 1. 2. Route the connector end of the power control harness toward the front corner of the stacker module along the same path as the secondary AC harness. Locate the 5-volt DC sense harness shipped with the electronics gate. The two ring lugs connect to the +5 volt and GND bus bars of the electronics gate. Refer to Figure 2-28. The tapped holes for attaching the leads to the buses are between the studs for the DC harnesses (installed later) and the power blocks securing the buses to the backplane.
Figure 228. 5-Volt DC Sense Harness Routing 3. 4. 5. 6. 7. Connect the plug P2 to the backplane at location J2. Feed the harness toward the terminals on the 5-volt power supply. This requires passing the harness through the fan plate. Plug the square connector into the J1 receptacle on the power supply. Plug the remaining connector into the power control harness that leads back to the IM. Coil the excess length under the equipment plate.
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Image Lift Power Cable

Use the following procedure to connect the image lift power cables. Refer to Figure 2-29. Locate the image lift power cables shipped coiled and attached to the side of the image camera box.
Figure 229. Image Lift Power Cable Routing 1. 2. 3. 4. 5. 6. 7. Uncoil the cable from the base of the IM, and disconnect the end of the cable plugged into the camera module. Locate the unused fan opening in the fan plate (front side). Route the cable through the empty fan opening. Pass the cable over the equipment panel and toward the rear of the machine. Route the cable to the rear of the module, and secure it to the underside of the video cable bracket with cable ties. Connect the rear camera power connector to J3 on the camera box. Connect the front camera power connector to J2 on the camera box. Connect P1 to the mating connector in the electronics gate, and rotate the collar to the locked position.
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15-Volt Harness
Use the following procedure to connect the 15-volt harness. 1. 2. Uncoil the harness from the base of the IM. Route the cable around the front of the power supply tray and toward the back of the tray between the 15-volt power supply and the lamp control PCBA. If the cable is too short for this route, route the cable directly from the power supply toward the rear of the tray. Route the cable to the underside of the video cable bracket, and secure the cable with cable ties. Locate the unused fan opening in the fan plate (front side). Route the cable through the empty fan opening. Pass the cable over the equipment panel and toward the rear of the machine. Secure the harness to the power supply tray, using the cable restraints of the power supply tray. Connect P14 to the connector in the electronics gate shroud and rotate the collar to the locked position.
3. 4. 5. 6. 7.
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Five-Volt Power Supply Cables

Use the following procedure to connect the 5-volt power supply cables to the backplane. Six white cables are supplied to connect the 5-volt power supply and the electronics gate backplane. Three are connected to the three +5 volt buses, and three are connected to the three ground buses on the backplane. Loosely attach the cables to the proper points on the buses, using the information in Figure 2-30 and the codes marked on the individual cables. The nuts are supplied in the electronics gate kit. Attach the ground lead of each power supply cable to one of the studs provided on the electronics gate shroud.
Figure 230. 5-Volt Power Supply Cable Connections 1. 2. Route the cables to the terminals of the supply. This requires passing the cables through the fan panel. Sort out and secure the cables to the supply, referring to Table 2-13. Note: Either "+" terminal can be used for the three +5 volt leads, but do not put all three leads on the same terminal. The same applies to the ground connections.
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Table 213. EMI 5-Volt Power Supply Connections
Part Number 4140 5788 4140 5770 4140 5796 4140 5804 4140 5796 4140 5770
Wire Designation +TM1 -TM2 +TM3 -TM4 +TM5 -TM6
Power Supply Designation +5 Volt 5 Volt Ground +5 Volt 5 Volt Ground +5 Volt 5 Volt Ground
Backplane Designation Top bus bar Second bus bar Third bus bar Fourth bus bar Fifth bus bar Bottom bus bar
3.
Install the 5-volt power supply EMI cover.
Video Cables
Use the following procedure to connect the video cables. Refer to Figure 2-31. Locate the two wide, black video cables coiled in the bottom of the IM. The ends of these cables are labeled "camera" and "digitizer." These labels also show the connector orientation and have a box that can be marked to distinguish the front camera cable from the rear camera cable. Mark one as front and the other as rear. 1. 2. 3. 4. 5. Place both video cables into the video cable bracket at the rear of the machine in such a way that the "camera" ends of the cables can plug into the camera box. Place the cables into the bracket with the label sides facing outside the module and the rear cable in the position toward the outside of the module. Plug the cables into the camera, and latch them in place. Be sure to observe the orientation indication and the front and rear designations. Route the "digitizer" ends of the cables through the slot in the fan panel at the rear of the machine. Lower the rear cable into the area in front of the gate. Plug the rear cable into the digitizer in slot 0. Be sure to observe the connector orientation indication. See Figure 2-31.
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Figure 231. Video Cable Routing 6. Plug the front video cable into the digitizer board in slot 28. Plug the cable in, and latch both cables to the front of the electronics gate.
Caution
Do not fold the video cable tight at any point. Flattening the cable into a tight fold may cause internal damage.
7.
Bundle the excess length of the video cables onto the video cable bracket with large cable ties.
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Lamp Power Supply Interface Cable

Use the following procedure to connect the lamp power supply interface cable. This harness has one end connected to the lamp control board and is coiled at the side of the IM with one plug at the other end. 1. Uncoil the harness and route along the cable bracket, as shown in Figure 2-32.
Figure 232. Lamp Power Supply Interface Cable Routing 2. 3. 4. Pass the cable through the slot in the fan panel along with the video cables already present. Connect the plug to the DTI board in card slot 16. Restrain the harness as indicated in Figure 2-32.
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Installing the JPEG and CCITT Electronics Gate

Note: The JPEG and CCITT image systems use the same JPEG electronics gate but have different boards and cabling. This section describes the common installation elements.
The JPEG electronics gate is installed under the baseplate of the right half of the first pocket module (pockets 3 through 6). The electronics gate is shipped with the parts necessary to install it in an eight-pocket module. Document processors with four-pocket modules must be upgraded to eight-pocket modules before installing the JPEG electronics gate. Refer to SEI 4139 5260. Use the following procedure to install the JPEG electronics gate in a document processor configured with eight-pocket modules. Note: Refer to "Installing the U4 Electronics Gate" earlier in this section for procedures to install a U4 electronics gate.
1.
Remove the front and rear panels from the IM and the first two eight-pocket modules (if they are on the machine). Remove the right end panel from the stacker module if the machine ends at the eighth pocket. Remove the fan panel located in the center of the 8-pocket module (if one exists), using the following steps: Note: a. b. Do not remove the fan panel at the end of the 8-pocket module.
2.
Remove the fan cables from the fans by pulling on the insulated connectors. Remove the four screws securing the fan panel to the frame, and remove the fan panel from the pocket module. The center fan panel is not used with the JPEG logic gate and will not be reinstalled.
Note:
3. 4.
Remove the pocket driver board and its hanger from the second four-pocket module. Remove the pocket drive belt tensioner arm, using an Allen wrench. Verify that the six holes in the pocket module frame required for the EMI ground straps are present. Refer to Figure 2-37 for hole locations. If any of the six holes are missing, drill the frame as required to mount the straps. Scrape away the paint around any holes you drill to provide metal-to-metal contact with the ground straps.
5. 6.
Remove the power supply and power supply cover frame and the power supply cover from the JPEG logic gate. Make sure that the four mounting holes for the JPEG gate have an exposed conductive area around them. Scrap away the paint as necessary. Install the JPEG electronics gate into the eight-pocket module frame. Note: The JPEG electronics gate installs from the rear of the machine and should be biased to the right during installation to clear the frame members. Two people should install the electronics gate to ensure that the gate is carefully guided into place.
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7.
Secure the rear right corner of the electronics gate to the eight-pocket module frame, using one 1/4-20 x 0.50 SEMS screw. You will need to pivot the electronics gate out of the way when installing the lower power supply unit mounting bracket later in this procedure. Note: There are several mounting screw positions provided in the gate to accommodate several variations of the eight-pocket module frame. Locate the correct mounting screw position by moving the gate as far to the right as possible (when looking at the gate from the rear), and inserting and tightening the mounting screw.
8. 9.
Reinstall the pocket drive belt tensioner arm and adjust it to the proper tension. Remove the access panel near the bottom of the gate if any sorter harnesses pass through this area to ensure that none are trapped or crushed beneath the gate.
10. Install the Lamp Controller Interconnect PCBA and video interconnect PCBAs onto the power supply unit cover mounting while it is outside the JPEG gate if these boards were not already factory installed. Refer to Figure 2-33 for the correct locations of the PCBAs.
Figure 233. Location of Lamp Controller Interconnect PCBA Interface and Video Interconnect PCBAs 11. Locate the lower power supply unit mounting bracket and attach it to the lower left side of the gate, using the 8-32 x 0.38 SEMS screws provided. You may need to pivot the electronics gate toward the rear to better access the screws and screw holes. 12. Place the 5/15 volt power supply unit on the lower power supply unit bracket mounting. The power terminals should face the rear, closer to the top of the gate.
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13. Install the upper power supply unit bracket mounting, using 8-32 x 0.38 SEMS screws. Refer to Figure 2-34 for the AC line filter location.
Figure 234. AC Line Filter Location 14. Install the power supply cover frame mounting onto the left side of the gate (when looking from the front of the gate) mounting flanges. Note: The power supply cover frame mounting fits on the outside of the mounting flanges on all three faces.
15. Install the 8-32 x 0.38 SEMS screws from the inside of the mounting flange on all three faces to secure the power supply unit cover frame mounting. Ensure that all screws are installed and tightened to comply with EMI regulations. 16. Wire the power supply with the DC power wires using the label on the wires. 17. Attach the AC wire to the AC filter located on the power supply cover. 18. Secure the remaining three corners of the electronics gate to the pocket module frame, using two 1/4-20 x 0.50 hex-head screws at the front and one 1/4-20 x0.50 SEMS screw at the rear. Refer to Figure 2-35 for the correct position of the bus bars.
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Figure 235. Correct Position of Bus Bars 19. Ensure that the 5 VDC distribution cables (copper bus cables) are plugged into the backplane. 20. Attach the 5 VDC distribution cables to the DC bus bars, using four 1/4-20 x 0.5 SEMS screws, each with a reduced O.D. 1/4 flat washer.
Caution
The DC bus bars and copper 5 VDC distribution cables create a high-current connection. Ensure that they are on tight to prevent thermal problems.
21. Tighten the nuts that secure the DC bus bars completely. 22. Fasten the AC harness to the power supply. 23. Use a digital ohmmeter to measure at least 0.5 ohms between the DC bus bars to ensure that no shorts exist between the logic ground and 5 VDC. 24. Install the internal cables. See Table 2-14. Note: Some cables listed in Table 2-14 were installed into the JPEG electronics gate at the factory. Use the information provided in Table 2-14 to ensure that the cables are connected correctly.
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Table 214. Internal Backplane Cable and Harness Connections
Cable or Harness 5 VDC #2 (factory installed) 5 VDC #2 (factory installed) 5 VDC #1 (factory installed) 5 VDC #1 (factory installed) 15 VDC camera (factory installed) 15 VDC auxiliary 15 VDC input PSU control Internal POL 1. J510, J511 2. PSU bus bar 1. J514, J515 2. PSU bus bar 1. J512, J513 2. PSU bus bar 1. J516, J517 2. PSU bus bar 1. J502 2. J531
Endpoints
1. J532 (factory installed) 2. PSU V2 and V3 1. J501 2. PSU V2 and V3 1. J503 2. PSU J1 1. FSD at J540 2A. POL receiver A 2B. POL transmitter B
Note:
The FSD is polarized. The ST connectors of this cable are marked "A" and "B" to correspond with the markings on the POL face plate.
Internal DTI (Lamp controller interface) Internal video (rear) Internal video (front) 15 VDC power fan
1. DTI interconnect board at J1 2. DTI board 1. Video interconnect board at J3 2. Rear image digitizer board (slot 0) 1. Video interconnect board at J4 2. Front image digitizer board (slot 28) 1. J518 (on fan drawer) 2. PSU V3
25. Route the harnesses over the power supply to the rear of the gate and attach the cables to their connectors identified in Table 2-15. Note: Make sure that the harnesses listed in Table 2-15 are attached to the power supply cover with 8-32 x 3/8 SEMS screws.
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Table 215. Harnesses Attached to the PS Cover
Cover PS cover PS cover PS cover PS cover PS cover
Cable or Harness 24 VDC sense DC ground CAR interface Point to point optical link (POL) interface--(JPEG only) DP interface 1. J504 2. J542
Endpoints
1. Feedthrough cap 2. 5 VDC ground bus bar 1. J506 2. J539 1. J543 2. To POL PCBA 1. J505 2. P538
26. Install the harnesses shown in Table 2-16. Note: When attaching the internal AC harness ring terminals to the connection studs on the AC line filter, take care not to apply excessive torque to the stud. This can rotate and cause internal damage. Instead, use two wrenches, one on each side of the ring terminal, to minimize torque on the stud. Table 216. AC Harnesses
Cable or Harness Safety ground Internal AC power
Endpoints 1. AC line filter input 2. Mounting lug on frame 1. AC line filter output 2. PSU AC inputs
Note:
See the JPEG Wiring Diagram (Figure 2-36) for harnessing information.
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(This page is left blank intentionally.)
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Caution
The internal POL cable has a minimum bend radius of 2 1/2 inches. Avoid bending this cable as much as possible.
27. Ensure that the following conditions are met to comply with EMI regulations: a. Six braided ground straps are installed from the JPEG image gate to the eightpocket frame module with one strap near each of the four upper corners and one strap at each of the two lower corners of the power supply cover. Refer to Figure 2-37.
Figure 237. EMI Ground Strap Locations
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b. c. d.
The safety ground wire from the AC line filter to the JPEG image gate is attached securely at both ends. The camera video cables are installed properly and clamped securely to the power supply cover frame. Four large ferrite beads are installed on each of the two camera 15-volt power harnesses. The harness external to the JPEG image gate should have four beads near the camera and between the end of the cable jacket and the connector. The internal cable should have four beads right behind the metal strain relief. One small ferrite block is snapped onto the internal DC logic ground wire within a half inch of the attachment to the bulkhead filter. Two medium ferrite blocks are snapped onto the internal 15-volt auxiliary source cable just behind the metal strain relief. Two medium ferrite blocks are snapped onto the internal AC power harness just below the attachments to the AC line filter. One large ferrite block is snapped onto each of the two internal video cables just before they attach to the video interconnect PCBA mounted inside the power supply cover frame. One rectangular ferrite block is snapped onto each of the two pairs of 5-volt bus cables just before they attach to the bus bars on the power supply.
e. f. g. h.
i.
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Connecting the External JPEG Image Cables

Use the following subsections to connect the external JPEG electronics gate cables to the Imaging Module. Use the procedure that corresponds to each cable. The external JPEG image cables are as follows: Lamp controller interface (DTI) cable 15-volt (auxiliary) harness Secondary AC harness 15-volt camera harness Document processor (DP) interface cable 24-volt bias harness Logic ground cable POL fiber optic cable CAR data cable Video cables (for front and rear camera)
Figure 2-38 shows the location of the connectors for each of the external cables.
Figure 238. Location of External Cable Connectors
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Lamp Controller Interface (DTI) Cable

Use the following procedure to connect the external lamp controller interface (DTI) cable: 1. Route the DTI cable along the bottom rear of the eight-pocket module to the camera module, as shown in Figure 2-39.
Figure 239. JPEG Lamp Controller Power and Interface Cable Routing 2. Plug one end of the cable onto J533 of the DTI interconnect board, and the other end onto J1 of the Image Lamp Control PCBA.
Lamp Controller (Auxiliary 15-Volt) Power Cable

Use the following procedure to connect the external lamp controller power cable: 1. 2. 3. Route the cable toward the rear of the camera module, along the rear of the eightpocket module, and toward the JPEG electronics gate. Refer to Figure 2-39. Plug the CPC end of the cable into J532, and rotate the collar to lock the cable in place. Plug the other end of the cable into J2 of the Image Lamp Control PCBA.
Secondary AC Supply Harness

Use the following procedure to connect the secondary AC supply harness: 1. Run the harness branch with the blue, brown, and green ring-terminated three-wire set along the back of the pocket module frame to the AC line filter on the side of the JPEG electronics gate.
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2.
Route the free end of the AC harness with the ring-terminated three-wire set and the external safety ground wire through the AC cable restraining clamp, and tighten it after making the following connections: a. b. c. Connect the brown wire to the input side of the AC line filter terminal closest to the JPEG electronics gate back frame member. Connect the blue wire to the input side of the AC line filter terminal closest to the middle of the PSU mounting frame. Connect the green and yellow safety ground wire to the ground terminal on the input side of the AC line filter and the external ground safety wire to the JPEG frame. Use one 8-32 SEMS nut at the filter and one 10-24 SEMS screw at the frame. Attach the AC line filter cover using the 8-32 SEMS nuts provided. Note: When attaching the external AC harness ring terminals to the connection studs on the AC line filter, take care not to apply excessive torque to the stud. This may rotate and cause internal damage. Use two wrenches, one on each side of the ring terminal, to minimize torque on the stud.
d.
3.
The following instructions are for JPEG retrofit installations only: The end of the AC harness with six ring-terminated wires connects to two of the circuit breakers at the rear of the IM. a. b. Connect the larger gauge blue and brown wires to the 20 AMP dual breakers in the quad breaker set. Connect the smaller gauge blue and brown wires to the separate 10 amp dual breaker. Ensure that the blue connects to blue and that brown connects to brown. Connect both green and yellow safety ground wires to the ground stud in the circuit breaker box and then reinstall the circuit breaker cover and remount the unit to the IM frame.
c.
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15-Volt Camera Harness

Use the following procedure to connect the 15-volt camera harness: 1. Route the harness along the back of the pocket module. Refer to Figure 2-40.
Figure 240. JPEG 15-Volt Camera Power Cable Routing 2. 3. Connect the male camera power cable (CPC) shell connector to the large CPC connector at J533, and rotate the collar to lock the connector in place. Connect each branch of the harness to the six-pin connectors. Either branch can connect to either of the six-pin connectors.
Document Processor Interface Cable

Use the following procedure to connect the external DP interface cable: 1. 2. 3. 4. Route the cable along the rear of the machine toward the frame. Lay the cable in the trays beneath the AA gate. Provide enough slack between the cable trays to allow the gate to swing open without pulling on the cable. For DL1 DP 1800/1825 sorters, plug the cable into AAJ25. For DL2 DP 1800/1825 sorters, plug the cable into AAJ12. For NDP units, plug the cable into AAJ25. Plug P15 into J538 of the power supply unit cover panel on the JPEG electronics gate.
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24-Volt Sense Harness

Use the following procedure to connect the external 24-volt sense harness: 1. 2. Connect the 9-pin end to J541 of the JPEG electronics gate power supply unit cover panel, and mate the connector to the cover panel with the captive screws provided. Feed the red and black wire terminated pair through the basic unit, passing under the hardware and submodules in the bottom of the frames. For DL 1 and 2, secure the red lead to TB2-B6 below area 1. Secure the black lead to TB2-B10 below area 1. Refer to Figure 2-41. For NDP, secure the leads to the 24V plug IM1.
Figure 241. JPEG 24-Volt Bias Harness Routing
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Logic Ground Cable

Use the following procedure to connect the external logic ground cable: 1. Temporarily disconnect the lamp controller interface (DTI) cable from J533 of the JPEG electronics gate power supply unit cover frame before measuring for a logic to frame short. Use a digital ohmmeter to measure at least 0.5 ohms between the logic ground (the negative terminal on the power supply unit) and the pocket module frame. Note: 3. 4. 5. 6. Do not continue this procedure if a short exists.
2.
Reconnect the lamp controller interface (DTI) cable to J533. Attach one end of the cable to the EMI feed through capacitor in the PSU cover panel. Route the free end of the cable toward the AA logic gate following the same path as the 24 VDC bias harness. For DL 1 and 2, attach the cable to terminal TB2-A14 on the center post of the basic unit frame. For NDP, attach the cable to DC1B7.
POL Fiber Optic Cable

Note: The POL fiber optic cable is not used for CCITT.
Use the following procedure to connect the external POL fiber optic cable:
Caution
The POL cables have a minimum bend radius of 2 1/2 inches. Avoid bending these cables as much as possible.
1. 2. 3.
Locate the free end of the POL fiber optic cable that comes from the storage and retrieval module (SRM). Feed the free end into the frame of the adjoining pocket module by routing the cable through the access panel in the module cover. Connect the cable to the external side of the duplex coupling at J540.
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CAR Data Cable

Use the following procedure to connect the CAR data cable: 1. 2. 3. Locate the free end of the CAR data cable that comes from the sorter's I/O box. Feed the free end into the frame of the adjoining pocket module by routing through the access panel in the module cover. Connect the cable to the external side of J540, using the SEMS screws provided.
Video Cables
To connect the JPEG external video cables, uncoil the front and rear video cables from the shipping container. The ends of these cables are labeled "camera" and "digitizer." These cables also show the connector orientation and have a box that can be marked to distinguish the front camera cable from the rear camera cable. Mark one as "front" and the other as "rear." Use the following procedure to connect the external video cables: 1. 2. 3. 4. Route both video cables along the rear of the pocket module. Plug the cable ends marked "camera" into the camera and latch them in place. Be sure the cables are oriented correctly for the front and rear cables. Route the ends marked "digitizer" to the front of the gate. Plug the end of the rear video cable into J1 of the Video Interconnect PCBA and the end of the front video cable to J2.
Caution
Although these cables are keyed, they can be forced into an improper orientation if too much force is applied.
5.
Secure both cables to the PSU mounting frame using the 1/4-20 SEMS nuts provided.
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Installing Dual Imaging Module Interface Cables

To complete the installation of the dual IM, the interface cables must be routed. Follow these steps. 1. Connect the Image Interface cable to JX513. This connector has screwlocks. Route the cable under the logic gate and then through the routing channels at the rear of the sorter to the AA logic gate. Route the cable up the right side of the AA logic gate, across the top, and down to the connector P3 on the Dual Image Interface Board PCBA. Clip the connector onto P3. Connect one end of the PCI3 interface cable to backplane connector J513. Route the cable down below the image logic gate and have the cable exit at the rear of the module. Connect the other end to PCI3 PCBA in the Image Capture Server. Install the remote on/off harness. Connect it to the point indicated on the label on the harness. On DL3 document processors, this point is at TBCD1. On DL1 and DL2 document processors, this point is at TB1 and TB2.
2.
3.
Figures 2-42 and 2-43 show the backplane connectors for the NDP 1000 and NDP 1825. Figures 2-44 and 2-45 shows the block wiring diagrams for these document processors.
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J544
JA C 620 JB B 520
JB 541 JB 540
JS 541 3J
JB F 520 JS 540 JF 540 4J 1J 7J JF 610 8J JA F 520 JF 513 JX 513
5J
2J
JB 610
JS 610
JB C 620 J511
6J
9 60 4
Figure 242. NDP 1150 Backplane Connectors
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Figure 243. NDP 1825 Backplane Connectors * J511 is only present on 13 slot backplane.
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Figure 244. NDP 1150 Dual Image Wiring Block Diagram
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Figure 245. NDP 1825 Dual Image Wiring Block Diagram * The Hardware CAR unit can only be used with a 13 slot backplane. SoftCAR is used with the 14 slot backplane.
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Installing ICS Components

The Image Capture Server (ICS) is a PC that is drop-shipped to the site. To configure this PC for use with the dual IM, PCI3 PCBA must be installed. Note: 1. 2. 3. 4. Before installing this PCBA, make sure that the power to ICS is off.
Remove the cover from the PC. Install the PCI3 PCBA into one of the PCI slots closest to the ISA slots. Reinstall the cover. Refer to the NDP 1000-4X/NDP 1825-4X Imaging Module Image Capture Server Software Installation and Operations Guide to verify CMOS settings and software installation. Connect the PCI3 interface cable to the PCI3 PCBAs connector. Reliable communications between the ICS and dual IM require that the ICS and document processor share a common power ground. Refer to SEI 3304 3035 Procedure For Verifying A Good Signal Reference Ground for recommended grounding practices.
5.
Note:
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U4 and JPEG IM Power Up and Check Out

Use the cable ties supplied with the IM to secure all harnesses to adjacent frame members or to other cables. The cables running through the stacker module between the camera and the electronics gate can be tied to the frame along the edge of the equipment plate. Replace all panels and adjust, if required, for best appearance of adjoining modules. Gaps should be approximately equal and straight. Perform the following procedure to power up and check out the IM and document processor: 1. 2. Perform the DP 1XXX pre-power on check out procedure. Refer to Section o2, Installation, in the DP 1800 Document Processor Operations Guide. Perform the IM pre-power on checks. For a U4 electronics gate, refer to SEI 3304 5402 found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." For a JPEG electronics gate, refer to SEI 4326 1379 found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." 3. 4. 5. 6. Close the circuit breaker panel and reset all breakers. Perform the DP 1XXX power on check out procedure. Refer to Section 2, "Installation," in the DP 1800 Document Processor Operations Guide. Perform the IM power on checks. Refer to SEI 3304 5402 found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." Perform the JPEG-specific checks for EMI compliance. Refer to SEI 3304 6343 Rev. B or later, found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." Perform one of the following: For a U4 system, install the front EMI cover on the electronics gate. For a JPEG system, install the front and rear EMI covers by placing the cover over the gate and finger-tightening the thumbscrews in the two corners. Then tighten the remaining screws with a screwdriver.
7.
8. 9.
Install all covers. Verify correct operation.
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Dual IM Power Up and Check Out

Use the cable ties supplied with the dual IM to secure all harnesses to adjacent frame members or to other cables. Perform the following procedure to power up and check out the dual IM and document processor: 1. 2. 3. 4. Ensure sure that all breakers on the document processor breaker panel are off and that power is removed from the document processor. Perform the document processor pre-power on check out procedure. Refer to the section on installation in the appropriate DP or NDP hardware installation guide. Verify that all AC and DC power connections in the dual IM are tight and that cables and fiber bundles are properly secured and kept away from moving parts. Check the following resistance checks: 5. The dual image power supply chassis to dual IM frame should be 0 ohms. Safety ground at the dual image power supply to the dual IM frame should be 0 ohms. AC (at the power supply) to the dual IM frame resistance should be greater than 25K ohm. AC (at the power supply) between the AC leads should be greater than 25K ohm.
With power removed, perform the dual image specific checks for EMI compliance. For DP units, refer to to SEI 3304 6343 Rev. C or later in Appendix A of this guide, Special Engineering Instructions and Tests and Adjustments. For NDP units, refer to SEI 2493 6296 Rev D. or later, found in Appendix A, Special Engineering Instructions and Tests and Adjustments. Close the circuit breaker panel and reset all breakers. Perform the document processor power-on check out procedure. Refer to the section on installation in the appropriate DP or NDP hardware installation guide. Power on the document processor. Verify that the logic gate and lamp cooling fans are running. Verify that the following voltages ( 0.1V) are present in the dual IM:
6. 7. 8. 9.
WARNING
High electrical currents exist on the dual image power supplies and backplane. An accidental short circuit created when using tools or wearing jewelry and contacting exposed circuits can cause eye injury or skin burns.
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1000 dual image +5.0V measured at the bus bars of the 5V power supply +17.7V measured at the lamp control PCBA between J570 pin 1 (+, top) and 4 (, bottom) +13.5V measured between JAF520 pin 6 (left center) and 2 (top center) 12.0V measured between JAF520 pin 6 (left center) and 5 (center) +5.0V (+/.1V) measured at the bus bars of the 5V power supply +17.7V measured at the lamp control PCBA between J570 pin 1 (+, top) and 4 (, bottom) +15.0V measured between JF600 pin 6 (left center) and 2 (top center) 12.0V measured between JF600 pin 6 (left center) and 5 (center) +15.0V measured between JB600 pin 6 (left center) and 2 (top center) 12.0V measured between JB600 pin 6 (left center) and 5 (center)
1825 dual image
10. Verify that the dual IM logic gate front cover is securely attached and the metal mesh air filter is in place. 11. Replace all document processor panels and adjust them if required to match the appearance of adjoining transport modules. Gaps in panels should be approximately equal and straight. 12. Verify correct operation using the document processor Exerciser program.
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Section 3 IC 1000/IC 1825 Imaging Module Components

This section shows the locations of the major components for the IC 1000/IC 1825 Imaging Module. Refer to Figures 3-1 through 3-3 to locate components in the IM and electronics gate. Refer to Figure 3-4 for U4 electronics gate PCBA locations and to Figure 3-5 for JPEG electronics gate PCBA locations.
Figure 31. Component Locator (Front)
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Figure 32. Component Locator (Rear)
Figure 33. Track Components
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Figure 34. U4 Electronics Gate PCBA Locator
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Figure 35. JPEG Electronics Gate PCBA Locator
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Section 4 Maintaining the IC 1000/IC 1825 Imaging Module

This section provides detailed procedures used in IC 1000/IC 1825 Imaging Module (IM) maintenance. Topics include maintenance philosophy, removal and replacement of field replacement modules (FRMs), tests and adjustments, and preventive maintenance.
Maintenance Philosophy
The Image Item Processing System (IIPS) and all its components include maintenance features that detect and diagnose unit faults in real time and monitor certain parameters during normal unit operation. Power-on confidence (POC) tests are executed during power-up time. The maintenance procedure includes the use of Image InfoAdvisor and the IIPS servicing guides. The steps for resolving IM problems are 1. 2. Use Image InfoAdvisor first Use IIPS servicing guides
The maintenance philosophy for the IM is FRM replacement to the printed circuit board assembly (PCBA) level. The logic is partitioned so that complete functions are contained on a single board to allow single-board diagnosis. Replacement of the backplane is performed if board replacement does not correct an operational failure. Additional information regarding the tools used for system diagnosis can be located in the IIPS servicing guides. Various topics include Exerciser programs POCs Maintenance test routines (MTRs) Communications tests Concurrent hardware tests IIPS logs System confidence test (SCT) System reconfiguration Image InfoAdvisor
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Field Replacement Modules (FRMs)

The IM is composed of the following FRMs, which are replaced on an as-needed basis: Cables and harnesses Camera box Circuit breakers Energy dump fan 15-volt power supply (U4 systems only) Image camera PCBA assemblies IM cooling fan Lamp control board Lamp cooling fan Lamp and enclosure Lamp power supply Power control PCBA (U4 systems only) Shutter sensor and actuator Track components Beam of lights Bearing housing and shaft assembly Belts Cover interlock switch Crown roller assembly Front frame and window assembly Idler assembly Rear frame and window assembly Track interlock switch and actuator
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Electronics Gate FRMs

The following FRMs are found in the electronics gate: Backplane Cables and harnesses Card guide Ejector 5-volt (U4) or 5/15 (JPEG) power supply Fan filter Fans PCBAs Refer to the IR 9210/IR 9220 Courtesy Amount Read (CAR) Module Servicing Guide: Installation and Maintenance for removal and replacement procedures for the CAR Port board and the video cables that connect the CAR Port board to the CAR module.
Note:
Imaging Module FRMs in the Document Processor

The following FRMs are found in the document processor: Image button light Image circuit breaker Image interface PCBA Image power line filter
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Imaging Module FRMs Removal and Replacement Procedures

The following subsections identify cables and harnesses and provide procedures for removal and replacement of FRMs found in the IM.
U4 Cables and Harnesses

Table 4-1 lists the U4 IM cables and harnesses, their locations, and their connectors. Table 41. U4 Imaging Module Cables and Harnesses
Cable Name 15-volt harness
Function 15-volt distribution
Connections 1. Terminal strip of 15-volt power supply 2. Connector J2 on lamp control board 3. Connector P14 on Electromagnetic Interference (EMI) shroud
24-volt bias harness
Reference voltage for IMRLY
1. 24-volt terminals on DP 1800 AA gate backplane 2. Connector J1 on power control unit
BOL interlock cable Camera assembly internal harness
Document tracking and track open signals Camera power, fan performance sensor, and camera sense signals
1. Slot 4 on AA gate backplane 2. Image track BOLs and track open switches 1. Bulkhead power connector for front electronic camera 2. Bulkhead power connector for rear electronic camera 3. Bulkhead monitor signal connector 4. Bulkhead fan performance sensor connector 5. Power connector on front electronic camera 6. Power connector on rear electronic camera
DP interface cable (external)
All document processor to image communications
1. MIIB connector J12 on DP 1800 AA gate backplane 2. Connector P15 on front EMI shield.
Image lift monitor cable
Fan sensor, camera sense signals to LC board
1. Connector J5 of lamp control board 2. Monitor connector on image lift
continued
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Table 41. U4 Imaging Module Cables and Harnesses (cont.)
Cable Name Image lift power cable (external)
Function 15-volt distribution to camera
Connections 1. Connector J1 on electronics gate front EMI shield 2. Front and rear (J2 and J3) camera power connectors on image lift
IM fan power harness
208 VAC distribution to all image fans
1. CAB-7 (P7) on DP 1800 AC control module 2. AC control module fan 3. Lamp cooling fan terminals 4. Imaging module cooling fan 5. Bulkhead connector on IM gate plenum 6. Energy Dump Cooling Fan
IM system ground cable
Image 5-volt ground
1. P 1800 TB2-14 2. Negative (-) power terminal on IM 5-volt power supply
Lamp control to power supply cable Lamp power cable
Lamp on/off and interface to power module; lamp status back Lamp start and run voltages to lamp/igniter
1. Connector J3 of lamp control board 2. Control connector on lamp power module 1. Lamp power connector on lamp power module 2. Lamp power connector on enclosure assembly
Lamp supply interface cable (external) Main AC power harness Power control harness
Serial lamp on/off to lamp control board, lamp, and fan; camera status back 208 VAC to image PDU
1. Connector J1 on lamp control board 2. Connector J1 on electronics gate rear EMI shield 1. DP 1800 PDU imaging circuit breaker 2. IM PDU circuit breakers
Off/On to 5-volt and 15volt power supplies
1. Connector J3 on power control unit 2. Power control terminals on 15-volt power supply 3. Power control connector on 5-volt DC harness
continued
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Table 41. U4 Imaging Module Cables and Harnesses (cont.)
Cable Name Secondary AC power distribution harness
Function 208 VAC distribution to image power supplies 1. Image PDU
Connections
2. Terminal strip on 15-volt power supply 3. Terminal strip on 5-volt power supply 4. Connector J3 on lamp power module
Shutter switch/energy dump harness Video cable
Shutter and energy dump fan sense signals to lamp control boards 16 channels of analog video, clock, and sync
1. Shutter switch 2. Energy dump fan sensor 3. Connector J4 on lamp control board 1. Connector J1 on electronic camera board 2. Connector J13 on image digitizer
JPEG Cables and Harnesses

Table 4-2 lists the cables and harnesses used with a JPEG system. Table 42. JPEG Imaging Module Cables and Harnesses
Cable Name DP interface cable (external) Front external video Rear external video External lamp controller interface External 15 VDC auxiliary
Function All document processor to image communications Analog video conduit
Connections 1. MIIB connector J12 on AA gate backplane 2. J538 on JPEG PSU panel 1. J2 of video interconnect 2. J1 of front camera card
Analog video conduit
1. J1 of video interconnect 2. J1 of rear camera card
Serial data to lamp control board 15 VDC distribution to image lamp control
1. J2 of DTI interconnect board 2. J1 of image lamp control 1. J532 JPEG PSU panel 2. J2 image lamp control
continued
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Table 42. JPEG Imaging Module Cables and Harnesses (cont.)
Cable Name External 15 VDC camera
Function 15 VDC distribution to front and rear camera boards 208 VAC distribution to JPEG and image lamp PSUs JPEG logic ground to frame ground path Document tracking and track open signals Camera power, fan performance sensor, and camera sense signals
Connections 1. J531 JPEG PSU panel 2A. Front camera power jack 2B. Rear camera power jack
External AC supply
1. Image circuit breakers 2A. AC line filter 2B. Image lamp PSU
External logic ground BOL interlock cable Camera assembly internal harness
1. EMI cap JPEG PSU 2. TB2-14 at DP 1800 1. Slot 4 on AA gate backplane 2. Image track BOLs and track open switches 1. Bulkhead power connector for front electronic camera 2. Bulkhead power connector for rear electronic camera 3. Bulkhead monitor signal connector 4. Bulkhead fan performance sensor connector 5. Power connector on front electronic camera 6. Power connector on rear electronic camera
Image lift monitor cable Lamp control to power supply cable Lamp power cable
Fan sensor, camera sense signals to LC board Lamp on/off and interface to power module; lamp status back Lamp start and run voltages to lamp and igniter
1. Connector J5 of lamp control board 2. Monitor connector on image lift 1. Connector J3 of lamp control board 2. Control connector on lamp power module 1. Lamp power connector on lamp power module 2. Lamp power connector on enclosure assembly
continued
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Table 42. JPEG Imaging Module Cables and Harnesses (cont.)
Cable Name Main AC power harness Shutter switch/energy dump harness
Function 208 VAC to image PDU
Connections 1. DP 1800 PDU imaging circuit breaker 2. IM PDU circuit breakers
Shutter and energy dump fan sense signals to lamp control boards
1. Shutter switch 2. Energy dump fan sensor 3. Connector J4 on lamp control board
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Camera Box
Use the following procedures to remove and replace the camera box.
WARNING
Be sure power is shut off to the IM before proceeding. Injury may result from electrical shock.
Removal 1. 2. 3. Turn off the power to the IM and document processor by turning off the main and image circuit breakers. Remove the IM front and rear covers. Use the following procedure to disconnect various cables: a. b. c. d. e. Disconnect the lamp power cable by removing the safety cover and hex nuts. Disconnect the two lift power cables from the camera board cover. Disconnect the image lift monitor cable the camera board cover. Disconnect the front and rear video cables from the camera board cover. Disconnect the IM fan harness at the quick-connect terminals. See Figure 4-1.
Figure 41. Camera Box
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f. 4. 5.
Disconnect the shutter switch/energy dump harness from the energy dump fan and the shutter sensor.
Loosen the rear transport flat belt. Refer to "Belts" later in this section. Use the following procedure to remove the optical towers: a. b. c. d. e. Remove the front optical gate wall assembly by pressing the release button and lifting the assembly straight up. Disengage the cylindrical lens covers from the base of each tower. Loosen the three captive screws securing the front optical tower. Remove front optical tower by pulling it straight up. Refer to Figure 4-2. Loosen the three captive screws securing the rear optical tower.
Figure 42. Optical Tower Removal f. 6. 7. 8. 9. Raise the rear optical tower, and remove the rear optical gate wall by removing the two screws and lifting out the wall. Lift the rear optical tower from the unit.
Remove the two socket head cap screws from the underside of the lamp enclosure. Remove the lamp enclosure. Remove the three hex head bolts securing the camera box to the baseplate. Slide the camera box out toward the rear of the IM.
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10. Remove the five screws from the underside of the camera box.
WARNING
Use two or more trained Unisys personnel to lift the camera box. Failure to do so may result in injury to personnel or damage to the camera box.
11. Remove the camera box. Replacement
WARNING
Use two or more trained Unisys personnel to lift the camera box. Failure to do so may result in injury to personnel or damage to the camera box.
1. 2.
Set the replacement camera box onto the carrier. Attach the underside of the camera box to the carrier with five shoulder screws. Ensure that the shoulders are inserted through the carrier mounting holes before tightening. Slide the camera box into the IM. Secure the camera box to the baseplate, using three hex head bolts. Attach the lamp enclosure to the camera box with two socket head screws on the underside of the enclosure. Install the front and rear optical towers, using the following procedure: a. b. c. d. e. f. g. Install the rear optical tower. Install the rear optical gate wall, using the two screws. Adjust the rear optical gate wall according to T&A 3304 4785 found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." Secure the rear optical tower, using the three captive screws. Install the front optical tower, and secure it, using the three captive screws. Reset the cylindrical lens covers at the base of each tower. Install the front optical gate wall assembly.
3. 4. 5. 6.
7.
Install the rear transport flat belt. Refer to "Belts" later in this section. Tension the belt according to T&A 3304 4124 found in Appendix A, "Special Engineering Instructions and Tests and Adjustments."
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8.
Use the following procedure to connect various cables: a. b. c. d. e. Connect the lamp power cable, using hex nuts and the safety cover. Connect the two lift power cables to the camera board cover.Connect the image lift monitor cable to the camera board cover. Connect the front and rear video cables to the camera board cover. Secure them with their connector screws. Connect the IM fan harness, using the quick-connect terminals. Connect the shutter switch/energy dump harness to the energy dump fan and shutter sensor.
9.
Reset all circuit breakers.
10. Replace the IM front and rear covers. 11. Use the following procedure to calibrate the IM lamp. If you encounter error messages during calibration, refer to Error Code Line Number 10300 in the Image Item Processing System (IIPS) Servicing Guide: Diagnostic Procedures for detailed information. a. Load and run the DP 1800 MTR disk. (If necessary, refer to the DP 1800 Servicing Guide: Maintenance Procedures for DL1 and DL2 for instructions.) The Main MTR Menu Screen appears. b. Select Image Module Tests (option 10). The Image Module Main Menu appears. c. Select POC Results (option 8). The IM POC test runs. If the test is successful, go to step d, next. If the test is unsuccessful, correct the problem using the image maintenance procedures in the Image Item Processing System (IIPS) Servicing Guide: Diagnostic Procedures.
d. e.
Select Calibrate Lamp (option 9) from the menu. Follow the instructions displayed on the screen to complete lamp calibration. If errors messages appear, refer to Error Code Line Number 10300 in the Image Item Processing System (IIPS) Servicing Guide: Diagnostic Procedures to resolve them.
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Circuit Breakers
Use the following procedure to replace one or both circuit breakers on the IM. Use the procedure under "Image Circuit Breaker" later in this section to replace the imaging circuit breaker found on the document processor. Removal 1. 2. 3. 4. 5. 6. 7. Turn off the power to the IM and document processor by turning off the main and image circuit breakers. Remove the IM rear cover. Remove four screws from the circuit breaker panel. Remove the panel by sliding it to the left and then pulling the right side out of the IM frame. Remove the three hex nuts from the circuit breaker cover. Remove the circuit breaker cover. Remove the screws from the terminals on the rear of the breaker. Note: There are four terminals on the lamp breaker and eight terminals on the logic breaker.
8. 9.
Note to which terminal each wire attaches, and remove the wires. Remove the four screws securing the circuit breaker to the panel.
10. Remove the circuit breaker. Replacement 1. 2. 3. 4. 5. 6. 7. Place the new circuit breaker into the panel from the rear. Attach the circuit breaker to the panel, using four screws. Attach each wire to the circuit breaker to the same terminal as on the old circuit breaker. Use screws to secure the wires to the terminals. Replace the circuit breaker cover, using three hex nuts. Replace the circuit breaker panel into the IM frame, and secure it with the four screws. Reset all circuit breakers. Replace the IM rear cover.
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Energy Dump Fan

Use the following procedure to remove and replace the energy dump fan. Refer to Figure 4-3.
Figure 43. Energy Dump Fan Removal 1. 2. 3. 4. 5. 6. 7. Turn off the power to the IM and document processor by turning off the main and image circuit breakers. Remove the IM rear cover. Disconnect the ground wires. Disconnect the IM fan power harness at the quick-connect terminals. Disconnect the rotation sensor branch of the shutter switch/energy dump harness. Remove the two screws securing the fan and guard. Remove the fan.
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Replacement 1. 2. 3. 4. 5. 6. Insert the new fan into the assembly. Connect the rotation sensor branch of the shutter switch/energy dump harness. Connect the IM fan power harness. Connect the ground wire. Attach the fan and guard with two screws. Replace the IM rear cover.
15-Volt Power Supply

Use the following procedure to remove and replace the 15-volt power supply. Refer to Figure 4-4. Removal
WARNING
1.
Turn off the power to the IM and document processor by turning off the main and image circuit breakers.
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Figure 44. 15-Volt Power Supply
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2. 3.
Remove the IM front and rear covers. Remove the two screws securing the power supply tray to the frame.
Caution
Use an open-end wrench to stabilize the terminals of the lamp power supply before removing the nuts that secure the lamp power cable. Rotating the studs will cause hidden damage inside the lamp power supply, resulting in premature failure.
4. 5. 6.
Disconnect the wires from the rear of the lamp power supply. Note the wire connections for reassembly. Pull the power supply tray forward out of the IM. Use the following procedure to disconnect various cables from the 15-volt power supply. Note the wire connections for reassembly. a. b. c. Disconnect the secondary AC harness from the AC power connector by removing the screws. Disconnect the 15-volt DC harness by removing the hex nuts and terminals from the studs on the power supply. Disconnect the power control harness by removing the hex nuts and terminals from the studs on the power supply.
7. 8.
Remove the two screws underneath the 15-volt power supply securing it to the power supply tray. Remove the 15-volt power supply.
Replacement
Caution
Do not use substitute screws to attach the power supply to the power supply tray. Penetration depth is critical. Using the wrong screws could result in damage to the power supply. Refer to the manufacturer's label for proper screw depth.
1. 2.
Attach the 15-volt power supply to the power supply tray, using the two screws. Use the following procedure to connect various cables to the 15-volt power supply. Be sure to connect the wires to the same terminals from which they were removed. a. b. c. d. Connect the power control harness to the power supply by placing the terminals over the studs and securing with hex nuts. Connect the 15-volt DC harness to the power supply by placing the terminals over the studs and securing with hex nuts. Connect the secondary AC harness to the power supply by placing the terminals over the studs and securing with hex nuts. Connect the lamp power supply wires to the rear of the lamp power supply.
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3. 4.
Slide the power supply tray into the IM, and secure it with two screws. Replace the IM front cover.
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Image Camera PCBA Assemblies

Use the following procedure to replace one or both of the image camera PCBA assemblies. Refer to Figure 4-5. Removal 1. 2. 3. Turn off the power to the IM and document processor by turning off the main and image circuit breakers. Remove the IM front and rear covers. Use the following procedure to disconnect various cables: a. b. c. 4. 5. 6. Disconnect the two lift power cables from the camera board cover. Note the wire locations for reassembly. Disconnect the image lift monitor cable from the camera board cover. Disconnect the front and rear video cables from the camera board cover.
Remove the screws securing the camera box side cover to the camera box. Remove the camera box side cover. Disconnect the internal camera harness from the camera board.
Figure 45. Image Camera PCBA Assembly 7. Remove the two cap screws securing the image camera PCBA assembly to the camera box. Do not remove the five hex head screws. The two cap screws are accessible through the large holes in the PCBA. Remove the image camera PCBA assembly.
8.
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Replacement 1. Set the two jumpers on the replacement PCBA to indicate which board you are replacing: Jumper 4 2. 3. 4. 5. 6. Front camera board: Use a jumper to connect pins 2 and 3 of jumper 4. Rear camera board: Use a jumper to connect pins 1 and 2 of jumper 4.
Jumper 6 DP 18XX Transport (300 IPS): Use a jumper to connect pins 1 and 3 of jumper 6. DP 10XX Transport (150 IPS): Use a jumper to connect pins 2 and 3 of jumper 6.
Locate the image camera PCBA on the alignment pins of the camera box. Secure image camera PCBA assembly to the camera box, using two screws. Attach the internal camera harness. Attach the camera box side cover to the camera box, using screws. Use the following procedure to connect various cables: a. b. c. Connect the two lift power cables to the camera board cover. Be sure to connect the wires to the same terminals from which they were removed. Connect the image lift monitor cable to the camera board cover. Connect the front and rear video cables to the camera board cover. Secure them with their connector screws.
7. 8.
Reset all circuit breakers. Use the following procedure to calibrate the IM lamp. If you encounter error messages during calibration, refer to Error Code Line Number 10300 in the Image Item Processing System (IIPS) Servicing Guide: Diagnostic Procedures for detailed information. a. b. c. Load and run the MTR disk. The Main MTR Menu Screen appears. Select Image Module Tests (option 10). The Image Module Main Menu appears. Select POC Results (option 8). The IM POC test runs. If the test is successful, go to step d, next. If the test is unsuccessful, correct the problem using the image maintenance procedures in the Image Item Processing System (IIPS) Servicing Guide: Diagnostic Procedures.
d. e.
9.
Replace the IM front and rear covers.
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IM Cooling Fan
Use the following procedure to remove and replace the IM cooling fan. Refer to Figure 4-6.
Figure 46. IM Cooling Fan Removal
WARNING
1. 2. 3. 4.
Turn off the power to the IM and document processor by turning off the main and image circuit breakers. Remove the IM front cover and right side panel. Remove the four screws and nuts securing the fan and its front and rear guards to the IM frame. Set the guards aside. Disconnect the IM fan harness from the fan.
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Replacement 1. 2. 3. Connect the IM fan harness to the fan. Be sure that the air flows into the module. Attach the front fan guard, fan, and rear fan guard to the IM frame, using four screws and nuts. Replace the IM front cover and right side panel.
Lamp and Enclosure

Use the following procedure to remove and replace the lamp and its enclosure. Refer to Figure 4-7.
Figure 47. Lamp and Enclosure
WARNING
The lamp is fragile. Explosion is possible if the lamp is damaged. Injury to personnel may result.
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Removal
WARNING
1. 2. 3. 4. 5. 6. 7. 8.
Turn off the power to the IM and document processor by turning off the main and image circuit breakers. Remove the IM front cover. Loosen the three screws from the top of the baseplate extension cover. Lift up and remove the baseplate extension cover. Disconnect the fan sensor cable from the camera enclosure. Remove the two screws from the fan enclosure cover. Remove the fan enclosure cover. Remove the front shipping/safety cover from the new lamp assembly, and install it on the old lamp assembly.
Caution
Use an open-end wrench to stabilize the terminals of the lamp enclosure before removing the nuts that secure the lamp power cable. Rotating the studs will cause hidden damage inside the lamp power supply, resulting in premature failure.
9.
Disconnect the lamp power cable by removing the safety cover and two hex nuts.
10. Remove the two hex cap screws from the underside of the lamp enclosure. 11. Remove the lamp enclosure. Pack it in the replacement lamp container, and follow standard rework procedures. Replacement 1. 2. 3. 4. 5. 6. 7. Examine the new lamp enclosure and ensure that all connections are secure. Replace the lamp enclosure in the IM and fasten with two hex head cap screws to the underside of the enclosure. Attach the fan enclosure cover, using two screws. Connect the lamp power cable, using hex nuts and safety cover. Connect the fan sensor cable to the camera enclosure. Replace the baseplate extension cover, and tighten the three screws. Reset all circuit breakers.
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8.
Use the following procedure to calibrate the IM lamp. If you encounter error messages during calibration, refer to Error Code Line Number 10300 in the Image Item Processing System (IIPS) Maintenance Manual for detailed information. a. Load and run the DP 1800 MTR disk. (If necessary, refer to the DP 1800 Servicing Guide: Maintenance Procedures for DL1 and DL2 for instructions.) The Main MTR Menu Screen appears. b. Select Image Module Tests (option 10). The Image Module Main Menu appears. c. Select POC Results (option 8). The IM power-on confidence (POC) test runs. If the test is successful, go to step d, next. If the test is unsuccessful, correct the problem using the image maintenance procedures in the Image Item Processing System (IIPS) Servicing Guide: Diagnostic Procedures.
d. e.
9.
Replace the IM front cover.
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Lamp Control PCBA

Use the following procedure to replace the lamp control board. Refer to Figure 4-8. Removal 1. 2. 3. 4. 5. 6. Turn off the power to the IM and document processor by turning off the main and image circuit breakers. Remove the IM front and rear covers. Disconnect the flat image lift monitor cable from connector J4 at the connector bulkhead area of the camera box. Remove the three AC wires from the retainers at the right front of the tray to provide necessary slack. Remove the two bolts securing the power supply tray to the frame. Pull the power supply tray forward as far as possible.
Figure 48. Lamp Control PCBA
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7.
Use the following procedure to disconnect various cables from the lamp control board: a. b. c. d. Disconnect the lamp control-to-power module interconnect cable. Disconnect the image lift monitor cable. Disconnect the image module power control cable. Disconnect the 15-volt DC harness.
8. 9.
Remove the two nuts securing the lamp control board bracket to the power supply tray. Remove the lamp control board and bracket.
10. Remove the four screws, nuts, and washers securing the lamp control board to the bracket. 11. Remove the lamp control board. Replacement 1. 2. 3. 4. Attach the lamp control board to the lamp control board bracket, using four screws, nuts, and washers. Be sure that the power supply tray is pulled out. Attach the lamp control board bracket to the power supply tray by seating the bracket over the two studs and securing it with two nuts. Use the following procedure to connect various cables to the lamp control board: a. b. c. d. 5. 6. 7. 8. 9. Connect the 15-volt DC harness to the board. Connect the image module power control cable to the board. Connect the image lift monitor cable to the board. Secure the cable with screws. Connect the lamp control-to-power module interconnect cable to the board.
Slide the power supply tray into the IM, and secure it, using two bolts. Secure the AC wiring bundle in the retainers at the right front of the power supply tray. Connect the flat image lift monitor cable to connector J4 at the rear of the camera box. Reset all circuit breakers. Use the following procedure to calibrate the IM lamp. If you encounter error messages during calibration, refer to Error Code Line Number 10300 in the Image Item Processing System (IIPS) Servicing Guide: Diagnostic Procedures for detailed information. a. Load and run the DP 1800 MTR disk. (If necessary, refer to the DP 1800 Servicing Guide: Maintenance Procedures for DL1 and DL2 for instructions.) The Main MTR Menu Screen appears. b. Select Image Module Tests (option 10). The Image Module Main Menu appears.
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c.
Select POC Results (option 8). The IM POC test runs. If the test is successful, go to step d, next. If the test is unsuccessful, correct the problem using the image maintenance procedures in the Image Item Processing System (IIPS) Servicing Guide: Diagnostic Procedures.
d. e.
10. Replace the IM front and rear covers.
Lamp Cooling Fan

Use the following procedure to replace the lamp cooling fan. Refer to Figure 4-9.
Figure 49. Lamp Cooling Fan
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Removal
WARNING
1. 2. 3. 4. 5. 6. 7.
Turn off the power to the IM and document processor by turning off the main and image circuit breakers. Remove the IM front cover and filler panel. Disconnect the ground wires from the fan by removing the hex nut securing the two ring terminals. Disconnect the IM fan power harness at the quick-connect terminals. Disconnect the fan performance sensor cable from the side of the camera box. Cut the plastic cable ties securing the cable to the IM frame. Remove the two screws and spacers securing the fan and plastic insulator. Remove the fan.
Replacement 1. 2. 3. 4. 5. 6. 7. Insert the new fan into the assembly. Attach the fan and plastic insulator with two screws and spacers. Connect the fan performance sensor cable to the side of the camera box. Secure the cable to the IM frame, using plastic cable ties. Connect the IM fan power harness, using hex nuts. Connect the ground wire. Reset all circuit breakers. Replace the IM front cover and filler panel.
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Lamp Power Supply

Use the following procedure to remove and replace the lamp power supply. Refer to Figure 4-10.
Figure 410. Lamp Power Supply Removal
WARNING
1. 2. 3.
Turn off the power to the IM and document processor by turning off the main and image circuit breakers. Remove the IM front and rear covers. Use the following procedure to disconnect various cables from the lamp control board: a. b. c. d. Disconnect the lamp control-to-power module interconnect cable. Disconnect the image lift monitor cable. Disconnect the image module power control cable. Disconnect the 15-volt DC harness.
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4. 5. 6.
Remove the two bolts securing the power supply tray to the frame. Pull the power supply tray forward out of the IM. Use the following procedure to disconnect various cables from the lamp power supply: a. b. Disconnect the lamp control-to-power module cable from the power supply. Disconnect the secondary AC harness by removing the hex nuts and terminals from the studs on the power supply.
Caution
c. 7. 8. 9.
Disconnect the lamp power cable by removing the hex nuts and pulling the terminals off the studs on the power supply.
Stand the power supply tray up on its rear end. Remove the two bolts underneath the lamp power supply securing it to the power supply tray. Remove the lamp power supply.
Replacement 1. Ensure that the power supply tray is pulled out.
Caution
Do not use substitute screws to attach the power supply to the power supply tray. Penetration depth is critical. Using the wrong screws could result in damage to the power supply. Refer to the manufacturer's label for proper screw depth.
2. 3.
Attach the lamp power supply to the power supply tray, using four screws. Use the following procedure to connect various cables to the lamp power supply:
Caution
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a. b. c. 4.
Connect the lamp power cable to the power supply by placing the terminals over the studs and securing it with hex nuts. Connect the secondary AC harness to the power supply by placing the terminals over the studs and securing it with hex nuts. Connect the lamp control-to-power module cable to the power supply.
Use the following procedure to connect various cables to the lamp control board: a. b. c. d. Connect the 15-volt DC harness to the board. Connect the image module power control cable to the board. Connect the image lift monitor cable to the board. Secure the cable with screws. Connect the lamp control-to-power module interconnect cable to the board.
5. 6. 7.
Slide the power supply tray into the IM, and secure it with two bolts. Reset all circuit breakers. Use the following procedure to calibrate the IM lamp. If you encounter error messages during calibration, refer to Error Code Line Number 10300 in the Image Item Processing System (IIPS) Servicing Guide: Diagnostic Procedures for detailed information. a. Load and run the DP 1800 MTR disk. (If necessary, refer to the DP 1800 Servicing Guide: Maintenance Procedures for DL1 and DL2 for instructions.) The Main MTR Menu Screen appears. b. Select Image Module Tests (option 10). The Image Module Main Menu appears. c. Select POC Results (option 8). The IM POC test runs. If the test is successful, go to step d, next. If the test is unsuccessful, correct the problem using the image maintenance procedures in the Image Item Processing System (IIPS) Servicing Guide: Diagnostic Procedures.
d. e.
8.
Replace the IM front and rear covers.
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Power Control PCBA

Use the following procedure to remove and replace the power control board. Refer to Figure 4-11. Removal
WARNING
Figure 411. Power Control PCBA 1. 2. 3. 4. 5. 6. 7. Turn off the power to the IM and document processor by turning off the main and image circuit breakers. Remove the IM rear cover. Remove four screws from the circuit breaker panel. Remove the circuit breaker panel by sliding it to the left and then pulling the right side out of the IM frame. Remove the two harnesses from the power control board. Remove the four screws securing the power control board to the circuit breaker panel. Remove the power control board.
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Replacement 1. 2. 3. 4. 5. Attach the power control board to the circuit breaker panel, using four screws. Attach the two connectors to the power control board. Replace the circuit breaker panel into the IM frame, and secure it with four screws. Reset all circuit breakers. Replace the IM rear cover.
Shutter Sensor and Actuator

Use the following procedure to remove and replace the shutter sensor and actuator. Refer to Figure 4-12.
Figure 412. Shutter Sensor Removal 1. 2. 3. 4. 5. Turn off the power to the IM and document processor by turning off the main and image circuit breakers. Open the IM front cover. Remove the shutter switch/energy dump harness from the shutter sensor. Note to which terminals the wires connect. Remove the two screws securing the shutter sensor bracket to the camera box. Remove the shutter sensor and bracket.
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6. 7.
Remove the two screws securing the shutter sensor and actuator to the bracket. Remove the shutter sensor and actuator.
Replacement 1. 2. 3. 4. 5. Attach the shutter sensor and actuator to the bracket, using the two screws. Attach the bracket to the camera box, using the two screws. Connect the shutter switch/energy dump harness to the shutter sensor. Be sure to connect the wires to the same terminals from which they were removed. Adjust the shutter sensor, using T&A 3304 5261 found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." Close the IM front cover.
Track Components
Use the following subsections to remove and replace IM components that are part of the document transport. Refer to Figure 4-13 for the location of each component.
Beam of Lights
Use the following procedure to remove and replace the beam of lights. The beam of lights are composed of two pieces: a photo-transistor that attaches to the rear track wall and a light emitting diode (LED) that attaches to the front track wall. Both pieces are shipped together and should be installed as a set. Removal 1. 2. 3. 4. 5. Turn off the power to the IM and document processor by turning off the main and image circuit breakers. Open the IM top cover. Unplug the beam of light pair. Remove the nut securing each piece. Remove the wire (if present) from the clips securing it to the base plate.
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Figure 413. Track Components 6. Remove each piece.
Replacement 1. 2. 3. 4. 5. 6. 7. 8. 9. Place the LED into the square socket in the front track wall. Secure the LED with the nut. Plug the LED into its associated connector. Place the photo-transistor into the round socket in the rear track wall. Secure the photo-transistor with the nut. Plug the photo-transistor into its associated connector. Secure the wire (if present) in the clips on the base plate. Adjust the photo-transistor, using T&A 2974 3333 found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." Close the IM top cover.
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Bearing Housing and Shaft Assembly

Use the following procedure to remove and replace the bearing housing and shaft assembly. Removal
WARNING
1. 2. 3. 4. 5. 6. 7. 8. 9.
Turn off the power to the IM and document processor by turning off the main and image circuit breakers. Open the IM top cover. Remove the rear covers to the IM and the first pocket module. Remove the flat belt above the base plate that touches the drive pulley. Refer to the procedure in the "Belts" subsection later in this section. Remove the nut securing the drive pulley to the assembly. Use a wrench on the flats on the bottom of the shaft to prevent the shaft from turning while removing the nut. Remove the drive pulley. Be sure to save the key. Remove the timing belts. Refer to the "Belts" subsection later in this section. Remove the three screws securing the assembly to the base plate. Remove the bearing housing and shaft assembly.
10. Remove the pulleys and spacers from the assembly and save them for replacement. Note in which order they are assembled. Replacement 1. 2. 3. 4. 5. Attach the pulleys and spacers to the bearing housing and shaft assembly in the order in which they were disassembled. Attach the bearing housing and shaft assembly to the base plate, using three screws. Assemble the top pulley and key onto the shaft. Attach the drive pulley to the assembly, using a nut. Replace the belts, and adjust them according to the following T&As found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." 6. 7. For timing belts, use T&A 3304 2078. For transport belts, use T&A 3304 4124. For drive belts, use T&A 3304 4793.
Replace the rear covers to the IM and the second pocket module. Close the IM top cover.
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Belts
Use the following procedure to remove and replace a belt. Refer to Figure 4-14 for belt, idler, and tensioner locations. Removal 1. 2. Open or remove the appropriate cover to expose the belt. Do one of the following: 3. 4. Disconnect the ribbon cable to the driver board if you are removing a timing belt. Skip to step 3 if you are removing any other belt.
Loosen the appropriate tensioner. Remove the belt.
Replacement 1. Install the belt around the crown roller or pulley. Ensure that the belt is seated properly.
Figure 414. Belt, Idler, and Tensioner Locations
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2.
Adjust the belt according to the following T&As found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." For the timing belt, use T&A 3304 2078. For transport flat belts, use T&A 3304 4124. For the drive belts, use T&A 3304 4793.
3. 4.
Reset all circuit breakers. Close or replace the cover.
Cover Interlock Switch

Use the following procedure to remove and replace the cover interlock switch. Removal 1. 2. 3. 4. Turn off the power to the image gate by turning off the power switch on the document processor panel. Open the IM top cover. Disconnect the wire to the switch. Squeeze each end of the switch, and pull it straight up to remove.
Replacement 1. 2. 3. 4. Set the switch into the socket, and push it in to lock. Connect the wire to the switch by pushing the connector on the terminal. Adjust the switch, using T&A 2974 3614 found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." Close the IM top cover.
Crown Roller Assembly

Use the following procedure to remove and replace a crown roller assembly. Removal 1. 2. 3. 4. Turn off the power to the image gate by turning off the power switch on the document processor panel. Open the IM top cover. Remove the belt that touches the crown roller. Refer to the belt removal procedure earlier in this section. Perform the following steps if the crown roller is located along the track: a. b. 5. Loosen the track wall by loosening the hex head screws. Move the track wall aside so that the crown roller clears the wall.
Use a screwdriver to remove the e-ring from the top of the crown roller assembly.
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6.
Pull up on the crown roller assembly to remove. Note the placement of the washers and the crown roller.
Replacement 1. 2. 3. 4. 5. Place the washers and crown roller on the shaft in the same order as removed. Snap the e-ring into place over the shaft to secure the crown roller assembly. Adjust the track wall, using T&As 3304 4082 and 3304 4108 found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." Replace the belt and adjust it, using T&A 3304 4124 found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." Close the IM top cover.
Front Frame and Window Assembly

Use the following procedure to remove and replace the front frame and window assembly. Refer to Figure 4-15.
Figure 415. Front Frame and Window Assembly Removal 1. 2. Turn off the power to the IM and document processor by turning off the main and image circuit breakers. Open the IM top cover.
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3. 4.
Remove the optical gate wall assembly by pushing on the release button and pulling the gate straight out. Remove the front frame and window assembly by sliding it out of the optical gate wall assembly.
Replacement 1. 2. 3. Slide the front frame and window assembly into the optical gate wall assembly. Attach the optical gate wall assembly by pushing it in place until it locks. Close the IM top cover.
Idler Assembly
Use one of the following procedures to remove and replace an idler assembly. Refer to Figure 4-14 for idler assembly and tensioner locations. Front Left Idler Pulley Use the following procedure to remove and replace the front left idler pulley. Removal 1. 2. 3. 4. 5. 6. 7. 8. 9. Open the IM top cover. Remove the IM front cover, filler panel, rear cover, and the microfilmer rear cover. Loosen the lock nut on the top of the belt tensioner. Refer to Figure 4-14 for the associated tensioner. Loosen the post on the belt tensioner to loosen it from the t-nut. Remove the microfilm drive belt. Remove the lock nut from the idler pulley. Loosen the post on the idler pulley. Slide the idler to the right, and remove the other drive belt. Remove the t-nut from the idler assembly. Remove the idler assembly.
10. Remove the bearing and pulley assembly by removing the arc clip and spacer and pulling the assembly off the shaft. Replacement 1. 2. 3. 4. Place the bearing and pulley assembly on the shaft, and secure it with an arc clip and spacer. Attach the shaft and idler pulley assembly to the base plate, using a t-nut. Do not tighten the nut. Replace the belts around the idler pulleys and tensioner. Replace the lock nut on the idler pulley. Do not tighten the nut.
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5. 6.
Adjust the belts according to T&A 3304 4793 found in Appendix A, "Tests and Adjustments and Special Engineering Instructions." Close the IM top cover. Replace the IM front cover, filler panel, rear cover, and the microfilmer rear cover.
Front Right Idler Pulley Use the following procedure to remove and replace the front right idler pulley. Removal 1. 2. Open the IM top cover. Remove the shield from the reject pocket, using the following procedure: a. b. c. 3. 4. 5. 6. 7. 8. 9. Remove the two screws securing the shield to the base plate. Remove the one screw securing the shield to the pocket rear wall. Remove the shield.
Remove the two screws securing the pocket floor to the pocket module base plate. Loosen the three screws securing the pocket floor to the IM base plate. Do not remove the screws. Remove the lock nut from the front left idler pulley. Loosen the post on the front left idler pulley. Slide the front left idler to the right to loosen the drive belt. Do not remove the drive belt. Remove the lock nut from the front right idler assembly. Unscrew the idler post from the t-nut.
10. Remove the idler assembly by dropping it through the two drive belts. 11. Remove the bearing and pulley assembly by removing the arc clip and spacer and pulling the assembly off the shaft. Replacement 1. 2. 3. 4. 5. 6. 7. Place the bearing and pulley assembly on the shaft, and secure it with an arc clip and spacer. Route the idler assembly through the drive belts. Attach the shaft and idler pulley assembly to the base plate, using a hex nut. Do not tighten the nut. Replace the lock nut on the idler pulley. Do not tighten the nut. Adjust the belts according to T&A 3304 4793 found in Appendix A, "Tests and Adjustments and Special Engineering Instructions." Tighten the three screws securing the pocket floor to the IM base plate. Secure the pocket floor to the pocket module base plate, using two screws.
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8.
Attach the shield to the reject pocket, using the following procedure: a. b. Attach the shield to the base plate, using two screws. Attach the shield to the pocket rear wall, using a screw.
9.
Close the IM top cover.
Rear Frame and Window Assembly

Use the following procedure to remove and replace the rear frame and window assembly. Refer to Figure 4-16. Removal 1. Open the IM top cover.
Figure 416. Rear Frame and Window Assembly 2. Remove the rear window and frame assembly by lifting it straight out.
Replacement 1. 2. Install the rear window and frame by sliding it straight into its slot. Close the IM top cover.
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Track Interlock Switch and Actuator

Use the following procedure to remove and replace one or both of the track interlock switches and/or their actuators: Removal 1. 2. 3. 4. 5. 6. 7. Turn off the power to the image gate by turning off the power switch on the document processor panel. Open the IM top cover. Remove the two hex head screws securing the switch bracket to the base plate. Remove the bracket. Disconnect the wires to the switch by pulling the connector off the terminals. Note to which terminals the wires connect. Remove the two screws securing the switch and its actuator to the bracket. Remove the switch and actuator.
Replacement 1. 2. 3. 4. 5. Attach the switch and its actuator to the bracket, using two screws. Be sure that the actuator is placed between the switch and bracket. Connect the wires to the switch by pushing the connectors on the terminals. Be sure to connect the wires to the same terminals from which they were removed. Attach the bracket to the base plate, using hex head screws. Adjust the switch, using T&A 3304 4116 found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." Close the IM top cover.
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U4 Electronics Gate FRMs

The following subsections provide procedures for removing and replacing FRMs in the U4 electronics gate.
Backplane
Use the following procedure to remove and replace the U4 backplane. Removal
Caution
1. 2. 3. 4. 5.
Turn off the power to the image gate by turning off the main and image circuit breakers. Remove the pocket module front and rear covers. Remove the video cables from the rear electro-magnetic interference (EMI) shield. Remove the front and rear shields by loosening the thumbscrews and pulling each shield. Remove the gate-external CAR video cable from the EMI shroud (if the CAR module is installed).
Caution
You must use a wrist strap when removing and replacing a PCBA. Failure to use a wrist strap could result in equipment damage from electrostatic discharge.
6. 7.
Disengage all the PCBAs from the image gate, but do not remove them from the image gate. Refer to "PCBAs" later in this section. Refer to Figure 4-17 as you disconnect various cables and harnesses: a. Do the following if CAR is installed: 1) Cut any cable ties holding the gate-internal CAR video cable to the bus bars. 2) Disconnect the gate-internal CAR video interface cable from the backplane at slot 24-P3, and remove the two screws holding it to the EMI shroud. b. c. Disconnect the internal lift power harness from backplane connectors J6 and J7. Disconnect the internal 15-volt harness from backplane connectors J1 and J4.
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d.
Disconnect the 5-volt DC harness sense wires from the backplane bus bar by unfastening the red and black pair. Back the harness out through the slot in the panel. Disconnect the 5-volt DC harness from backplane connector J2. Back the harness out through the slot in the panel. Disconnect the document processor interface cable from backplane connector J3. Disconnect the three 5-volt DC cables TM1, TM3, and TM5 (red tags) from the +5V bus bars and the three ground cables TM2, TM4, and TM6 from the ground bus bars by removing the hex nuts securing the terminals to the lugs. Disconnect the cables from the 5-volt power supply. Disconnect the three sets of EMI ground cables from the EMI shield. Remove the external DP interface cable from connector P15 on the EMI shield. Disconnect the internal DP interface cable from connector J3, and remove the two screws holding it to the shroud.
e. f. g.
h. i. j.
Figure 417. Backplane 8. 9. Remove the 32 screws securing the backplane to the image gate. Remove the backplane.
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Replacement 1. 2. 3. 4. Place the backplane into the image gate and secure the backplane loosely with 32 screws. Do not tighten the screws at this time. Install two PCBAs: one in the first slot and one in the last slot of the backplane. Be sure the PCBAs are seated firmly in the sockets of the backplane. Tighten the 32 screws, using two PCBAs for alignment. Use the following procedure to connect various harnesses and cables: a. Connect the three 5-volt DC cables TM1, TM3, and TM5 (red tags) to the +5V bus bars and the three ground cables TM2, TM4, and TM6 to the ground bus bars by securing the terminals to the lugs, using hex nuts. Connect the short wires first. Connect the three sets of EMI ground cables to the EMI shield. Attach the external DP interface cable to connector P15 on the EMI shroud. Secure the screws with a small amount of thread locking compound. Connect the internal DP interface cable and shroud to connector J3. Connect the document processor interface cable to the backplane at jumper J3. Connect the 5-volt DC harness to the backplane at jumper J2. Connect the 5-volt DC harness sense wires to the backplane bus bar, using screws to secure the red and black pair. Connect the 15-volt harness to the backplane at jumpers J1 and J4. Connect the lift power harness to the backplane at jumpers J6 and J7. Do the following if the CAR module is installed: 1) Reconnect the gate-internal CAR video cable to the backplane at slot 24-P3. Be sure pin 1 on the connector is up. 2) Reconnect the other end of the gate-internal CAR video cable to the EMI shroud. Secure the screws with thread locking compound. 3) Use cable ties to secure the cable to the bus bars as shown in Figure 4-17. 5. 6. 7. 8. 9. Replace all the PCBAs in the image gate. Refer to "PCBAs" later in this section. Replace the rear EMI shield and connect the image video cables to the shield. Connect the CAR gate-external video cable (if there is one) to the front EMI shroud, and replace the front EMI shield. Reset all circuit breakers. Replace the pocket module front and rear covers.
b. c. d. e. f. g. h. i. j.
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Cables and Harnesses

Table 4-3 lists the U4 image gate cables and harnesses, their locations, and their connectors. Table 43. U4 Image Gate Cables and Harnesses
Cable Name 15-volt harness (internal)
Function 15-volt distribution
Connections 1. Connector J14 on lamp control board 2. 15-volt connector J1 on backplane 3. 15-volt connector J4 on backplane
24-volt bias harness
Reference voltage for IMRLY High current DC for image gate 5-volt sense, PF to gate, remote on/off to 5-volt power supply
1. 24-volt terminals on DP 1800 AA gate backplane 2. Connector J1 on power control unit 1. 5-volt terminals of 5-volt power supply 2. Bus bars of backplane 1. Control connector of 5-volt power supply 2. Sense terminals on 5-volt bus bars 3. Power fail connector J2 on backplane 4. 5-volt power control connector on power control harness
5-volt DC harness
5-volt DC harness
DP interface cable
All document processor to image communications 15-volt distribution to camera Fan-to-fan power in plenum
1. MIIB connector J15 on electronics gate front EMI shield 2. MIIB connector J3 on IM gate backplane 1. Connector J1 on electronics gate front EMI shield 2. Connectors J6 and J7 on backplane 1. Bulkhead connector on IM gate plenum 2. Gate fan 3. Gate fan 4. Gate fan 5. Gate fan
Image lift power cable (internal)
IM gate fan harness
continued
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Table 43. U4 Image Gate Cables and Harnesses (cont.)
Cable Name Lamp supply interface cable (internal)
Function Serial lamp on/off to lamp control board, lamp, and fan; camera status back Compressed digital images to SRM
Connections 1. Connector J1 on electronics gate rear EMI shield 2. Connector J1 on DTI PCBA
POL internal cable
1. Fiber optic receiver and transmitter on POL board 2. FSD fiber optic duplex header in gate area
Card Guide
Use the following procedure to remove and replace a U4 card guide. Removal
WARNING
1. 2. 3. 4.
Turn off the power to the image gate by turning off the main and image circuit breakers. Remove the pocket module rear cover. Remove the video cables from the rear EMI shield. Remove the rear EMI shield by loosening the thumbscrews and pulling the shield.
Caution
5. 6.
Remove the PCBA from the card guide to be replaced. Refer to "PCBAs" later in this section. Remove the card guide.
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Replacement 1. 2. 3. 4. 5. 6. Attach the card guide to the frame. Replace the PCBA. Refer to "PCBAs" later in this section. Replace the rear EMI shield. Connect the video cables to the rear EMI shield. Reset all circuit breakers. Replace the pocket module rear cover.
Ejector
Use the following procedure to remove and replace a PCBA ejector in a U4 electronics gate. Removal
WARNING
1. 2. 3. 4.
Turn off the power to the image gate by turning off the main and image circuit breakers. Remove the pocket module rear cover. Remove the video cables from the rear EMI shield. Remove the rear EMI shield by loosening the thumbscrews and pulling the shield.
Caution
5. 6. 7.
Remove the PCBA. Refer to "PCBAs" later in this section. Remove the screw securing the ejector to the PCBA. Remove the ejector.
Replacement 1. 2. 3. 4. Attach the ejector to the PCBA, using a screw. Replace the PCBA. Refer to "PCBAs" later in this section. Connect the video cables to the rear EMI shield. Replace the rear EMI shield.
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5. 6.
Reset all circuit breakers. Replace the pocket module rear cover.
5-Volt Power Supply

Use the following procedure to remove and replace the U4 5-volt power supply. Refer to Figure 4-18.
Figure 418. 5-Volt Power Supply Removal
WARNING
1. 2. 3. 4.
Turn off the power to the image gate by turning off the main and image circuit breakers located in the document processor main breaker box. Remove the pocket module front and rear covers. Disconnect the CAR video cable (if there is one) from the front EMI shield, then remove the shield by loosening the thumbscrews and pulling off the shield. Remove the front cover of the power supply EMI shroud by loosening the thumbscrews and pulling off the cover.
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5.
Use the following procedure to disconnect various harnesses and cables: a. Disconnect the six 5-volt DC cables from the V1 terminals on the power supply. Remove the other ends of the cables from the backplane by unscrewing the hex nuts and pulling the terminals off the bus bars. Disconnect the 5-volt DC harness from the power supply. Disconnect the secondary AC harness by unscrewing the three screws from the AC line terminal strip and pulling the stripped wires free. Disconnect the image power supply ground wire.
b. c. d.
Caution
The power supply EMI shroud has sharp edges that may damage cables or injure personnel. Use caution when removing the shroud.
6. 7. 8. 9.
Remove the EMI shroud from the power supply by removing the two hex screws and pulling the shroud up and over the power supply toward the front of the machine. Remove the four hex head bolts securing the power supply bracket to the frame. Remove the power supply and its bracket. Remove the four screws securing the power supply to the power supply bracket.
10. Remove the 5-volt power supply. Replacement
Caution
Do not use substitute screws to attach the power supply to the power supply bracket. Penetration depth is critical. Using the wrong screws could result in damage to the power supply. Refer to the manufacturer's label for proper screw depth.
1. 2.
Attach the 5-volt power supply to the power supply bracket, using four screws. Attach the bracket to the image gate by placing the bracket over the studs and securing it with four hex bolts.
Caution
The power supply EMI shroud has sharp edges that may damage cables or injure personnel. Use caution when replacing the shroud.
3.
Place the EMI shroud over the power supply through the front of the machine. Secure the shroud to the power supply bracket, using hex screws.
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4.
Use the following procedure to connect various cables and harnesses: a. b. c. d. Connect the image power supply ground wire. Connect the secondary AC harness by inserting the stripped ends of each of the three wires into the AC line terminal strip and securing them with screws. Connect the 5-volt DC harness to the power supply. Connect the six 5-volt DC cables to the power supply by placing each of them onto their appropriate V1 terminal lugs and securing them with four hex nuts. Be sure that cables TM1, TM3, and TM5 (red labels) are attached to the + terminals and that cables TM2, TM4, and TM6 are attached to the - terminals. Either terminal may be used, but do not put all three wires on one terminal. Connect the short wires first. Connect the other ends of the cables to the bus bars on the backplane. Refer to Figures 4-17 and 4-18.
5. 6. 7. 8.
Replace the front cover of the power supply EMI shroud. Replace the front EMI shield and reconnect the CAR video cable (if there is one). Reset all circuit breakers. Replace the pocket module front and rear covers.
Fan Filter
Use the following procedure to remove and replace the U4 fan filter. Removal 1. 2. 3. 4. 5. Turn off the power to the image gate by turning off the power switch on the document processor panel. Remove the pocket module rear cover. Remove the two hex nuts securing the retaining clips to the fan housing. Remove the retaining clips. Remove the filter by pulling the top edge forward and lifting it up.
Replacement 1. 2. 3. Replace the filter by inserting the bottom edge into the channel and pushing the top edge in. Attach the retaining clips to the fan housing, using hex nuts. Replace the pocket module rear cover.
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Fans
Use the following procedure to remove and replace any of the four U4 electronics gate fans. Refer to Figure 4-19.
Figure 419. Image Gate Fans Removal
WARNING
Shut off electrical power to the document processor before proceeding with replacing the fans. Injury may result from electrical shock. The document processor is hard-wired to the facility power supply. Power must be shut off from the facility circuit breaker panel. Check to be sure power has been shut off to the document processor before proceeding.
1. 2. 3. 4. 5. 6. 7.
Turn off the power to the IM and document processor by turning off the main and image circuit breakers. Remove the pocket module rear cover. Remove the two hex nuts securing the retaining clips to the fan housing. Remove the retaining clips. Remove the filter by pulling the top edge forward and lifting it up. Remove the two screws securing the fan to the fan housing. Remove the fan.
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8.
Disconnect the fan harness from the fan.
Replacement 1. 2. 3. 4. 5. Connect the fan harness to the fan. Place the fan in the housing, and secure it with the two screws. Be sure that the air flow is into the electronics gate. Replace the filter by inserting the bottom edge into the channel and pushing the top edge in. Attach the retaining clips to the fan housing, using hex nuts. Replace the pocket module rear cover.
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PCBAs
Use the following procedure to remove and replace a U4 electronics gate PCBA. Refer to Figure 4-20. Special Tools Anti-static wrist strap Static shielding bag
Removal 1. 2. Turn off the power to the image gate by turning off the main and image circuit breakers. Remove the pocket module rear cover.
Figure 420. Inserting a PCBA 3. 4. 5. Remove the video cables from the rear EMI shield. Remove the rear EMI shield by loosening the thumbscrews and pulling the shield. Use the wrist strap and ground it against the frame of the pocket module to guard against the possibility of electrostatic discharge.
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Caution
You must use a wrist strap when removing and replacing a PCBA. Failure to use a wrist strap could result in equipment damage from electrostatic discharge
6.
Locate the defective PCBA in the electronics gate by referring to the numbered label on the bottom plenum. Note: The image digitizer, diagnostic/transport interface, and POL PCBAs all have a cable that must be disconnected before the board can be removed.
Caution
When replacing the POL PCBA, be sure not to bend the fiber optic cable connected to it. Damage to the cable may result. Disconnect the cable before removing the PCBA.
7. 8. 9.
Loosen the screws on the ejector handles. The ejector handles are located at the top and bottom of the PCBA. Press outward on both ejector handles simultaneously to loosen the PCBA from the backplane. Remove the defective PCBA by sliding it out from the electronics gate. Place the defective PCBA in a static shielding bag.
Replacement 1. 2. Remove the replacement PCBA from its static shielding bag. Be sure that the jumpers are properly set on the PCBA. Refer to Table 4-4. Table 44. PCBA Jumper Settings
PCBA CDB POL
Jumper Settings H2-4 - H3-4* H1-H2* W1 W2 W3 W4 H1-2 - H1-3* W5 W6 W7 W9
Main processor
W8
W10
*Two position numbers (such as H2-4 - H3-4) indicate jumpering between the two positions.
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3. 4. 5. 6. 7. 8. 9.
Insert the PCBA into the slot. Press the PCBA into the backplane. Be sure the PCBA is seated firmly in all sockets. Tighten the screws on the ejector handles. Replace any cables that were disconnected. Replace the rear EMI shield. Connect the video cables to the rear EMI shield. Reset all circuit breakers.
10. Do one of the following: If the image digitizer PCBA was not replaced, skip to step 12. If the image digitizer PCBA was replaced, continue with step 11, next.
11. Use the following procedure to calibrate the IM lamp. If you encounter error messages during calibration, refer to Error Code Line Number 10300 in the Image Item Processing System (IIPS) Servicing Guide: Diagnostic Procedures for detailed information. a. Load and run the DP 1800 MTR disk. (If necessary, refer to DP 1800 Servicing Guide: Maintenance Procedures for DL1 and DL2 for instructions.) The Main MTR Menu Screen appears. b. Select Image Module Tests (option 10). The Image Module Main Menu appears. c. Select POC Results (option 8). The IM POC test runs. If the test is successful, go to step d, next. If the test is unsuccessful, correct the problem using the image maintenance procedures in the Image Item Processing System (IIPS) Servicing Guide: Diagnostic Procedures.
d. e.
Select Calibrate Lamp (option 9) from the menu. Follow the instructions displayed on the screen to complete lamp calibration. If errors messages appear, refer to Error Code Line Number 10300 in Section 6, "Manual Procedures," of the Image Item Processing System (IIPS) Maintenance Manual to resolve them.
12. Replace the pocket module rear cover.
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JPEG Electronics Gate FRMs

The following subsections provide procedures to remove and replace FRMs in the JPEG electronics gate.
Backplane
Use the following procedure to remove and replace the JPEG backplane. Removal 1. 2. 3. Turn off the power to the JPEG electronics gate by turning off the main and image circuit breakers. Remove the pocket module front and rear covers. Remove the front and rear EMI covers by loosening the thumbscrews and pulling each cover out.
Caution
Use an antistatic wrist strap during this procedure to reduce the possibility of electrostatic discharge (ESD). Failure to wear one could result in equipment damage and/or performance degradation now or in the future.
4. 5.
Disengage all PCBAs from the JPEG electronics gate, including the clock PCBA, but do not remove them completely from the gate. Disconnect the cables and harnesses listed in Table 4-5, and pull them out of the way. Refer to Figure 4-21 for the location of the backplane connectors. Table 45. JPEG Cables and Harnesses to Disconnect
Cable or Harness to Disconnect Internal CAR interface Internal 24 VDC bias Internal 15 VDC camera Internal 15 VDC In PSU control Internal DP interface J506 J504 J502 J501 J503 J505
Disconnect at
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Figure 421. JPEG Backplane Connectors 6. Disconnect both upper 5 VDC distribution cables at the gate (J510, J511, J512, and J513) and at the PSU bus bars. Remove the cables from the holders and place them in an area where they will not be bent. Disconnect both lower 5 VDC distribution cables at the gate (J514, J515, J516, and J517) and at the PSU bus bar. Note the location of the eight black cable holders, and remove the holders from the top and bottom of the backplane. Remove the remaining screws securing the backplane to the gate.
7. 8. 9.
10. Remove the backplane and disconnect J518 at the JPEG fan drawer if necessary for clearance. Replacement 1. Place the backplane into the JPEG electronics gate and loosely secure the backplane to the gate with eight screws (one at each corner and one at the top, bottom, right, and left sides). Install the two image digitizer boards and DTI board. Ensure that the boards are seated firmly in the backplane sockets. Insert and tighten the 32 screws, using the three boards for alignment. Be sure to install the 5 VDC cable holders in their proper position before tightening the screws. Reinstall the lower 5 VDC cables, securing them first to the JPEG backplane at J514, J515, J516, and J517, the cable holders, and then the PSU bus bars. Reinstall the upper 5 VDC cables, securing them first to the JPEG backplane at J510, J511, J512, and J513, the cable holders, and then the PSU bus bars. Reconnect the cables that were removed in Table 4-5, earlier in this subsection. Reengage all PCBAs, including the clock PCBA, into the JPEG backplane sockets.
2. 3. 4. 5. 6. 7.
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8. 9.
Replace the front and rear EMI covers. All screws must be attached to ensure continued EMI regulator compliance. Replace the front and rear pocket module covers.
10. Reset all circuit breakers.
Cables and Harnesses

Use Table 4-6 as a reference to remove and replace any faulty harnesses. Table 4-6 lists the JPEG image cables and harnesses, their locations, and their connections. Table 46. JPEG Image Gate Cables and Harnesses
Cable Name Internal DP interface Front internal video Rear internal video Internal POL
Function All document processor to image communications Analog video conduit
Connections 1. J538 JPEG PSU panel 2. J505 JPEG gate 1. Front ID board 2. J4 of video interconnect
Analog video conduit
1. Rear ID board 2. J4 of video interconnect
Full duplex fiber optic data between SRM and IM Full duplex fiber optic data between SRM and IM Serial data to lamp control board 5 VDC distribution to JPEG backplane Parallel digital data path to CAR system Parallel digital data path
1A. POL receiver (A)1B. POL transmitter (B) 2. J540 JPEG PSU panel 1. J540 JPEG PSU panel 2. SRM bulkhead connector 1. DTI board 2. J1 of DTI interconnect 1. JPEG gate PSU panel 2. J510-517 JPEG backplane 1. J506 JPEG 2. J539 JPEG PSU panel 1. J539 JPEG PSU panel 2. Interface panel on CAR
External POL
Internal lamp controller interface 5 VDC harness
Internal CAR interface External CAR interface Internal 24 VDC bias External 24 VDC bias
24 VDC sense from AA logic gate 24 VDC sense from AA logic gate
1. J504 JPEG2. J541 JPEG PSU panel 1. J541 JPEG PSU panel 2A. +24 on AA logic gate 2B. GND on AA logic gate
continued
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Table 46. JPEG Image Gate Cables and Harnesses (cont.)
Cable Name Internal 15 VDC auxiliary Internal 15 VDC camera 15 VDC input
Function 15 VDC distribution to image lamp control 15 VDC distribution to front and rear camera boards 15 VDC distribution to JPEG gate
Connections 1A. V3 JPEG PSU 1B. V2 JPEG PSU2. J532 JPEG PSU panel 1. J502 JPEG 2. J531 JPEG 1. J501 JPEG 2A. V3 of PSU 2B. V2 of PSU
PSU control
Control and sense of PSU
1. J503 JPEG 2. J1 of PSU
Internal AC
208 VAC distribution to JPEG PSU 15 VDC distribution to JPEG cooling fans JPEG logic ground to frame ground path Safety ground to frame
1. AC line filter 2. AC terminals JPEG PSU 1. J518 JPEG fan assembly 2. V3 of PSU 1. Logic ground JPEG PSU 2. EMI cap JPEG PSU panel 1. AC line filter ground 2. Lug on pocket frame
15 VDC fan power Internal logic ground External logic ground
Card Guide
Use the following procedure to remove and replace a JPEG electronics gate card guide. Removal
WARNING
1. 2. 3.
Turn off the power to the image gate by turning off the main and image circuit breakers. Remove the pocket module front cover. Remove the front EMI shield by loosening the thumbscrews and pulling the shield.
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Caution
4.
Remove the PCBA from the card guide to be replaced. Refer to "PCBAs" later in this section. Note: Two styles of card guides are used in JPEG electronic gates: one for larger PCBAs and another for smaller PCBAs. The larger PCBAs have six card guides in all, three above and three below, all of which are identical. The smaller PCBAs have two guide, one above and one below.
5.
Remove the card guide. To remove a larger PCBA card guide a. b. Pull up and forward on the rear end of the guide until it detaches from the mounting surface. Push the guide to the rear to unhook the forward end.
To remove a smaller PCBA card guide, pull the guide straight off the frame.
Replacement 1. Attach the card guide to the frame. To replace a larger PCBA card a. b. c. 2. 3. 4. 5. Hook the front end of the guide into the sheet-metal tray. Arch the guide to hook the rear end of the guide into place. Ensure that the guide is inserted in the correct direction (open and facing forward) or it may be difficult to insert PCBAs.
To replace a smaller PCBA card guide, press the guide until it snaps into place. This style of guide has no orientation and may be installed in either direction.
Replace the PCBA. Refer to "PCBAs" later in this section. Replace the front EMI shield. Reset all circuit breakers. Replace the pocket module front cover.
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Ejector
Use the following procedures to remove and replace a PCBA ejector in JPEG electronics gate. Removal - Small PCBA Ejector
WARNING
1. 2.
Turn off the power to the image gate by turning off the main and image circuit breakers. Remove the pocket module front cover.
Caution
3. 4. 5.
Remove the PCBA. Refer to "PCBAs" later in this section. Remove the screws securing the ejector to the PCBA and front panel. Remove the ejector.
Replacement 1. 2. 3. 4. 5. Attach the ejector to the PCBA and front panel, using screws. Replace the PCBA. Refer to "PCBAs" later in this section. Replace the front EMI shield. Reset all circuit breakers. Replace the pocket module front cover.
Removal - Large PCBA Ejector
WARNING
1. 2.
Turn off the power to the image gate by turning off the main and image circuit breakers. Remove the pocket module front cover.
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3.
Remove the front EMI shield by loosening the thumbscrews and pulling off the cover.
Caution
4.
Remove the PCBA with the faulty ejector. Refer to "PCBAs" later in this section. Note: Ejectors on this style of PCBA form part of the PCBA support rail, which is attached to the upper or lower edge of each PCBA.
5.
Perform one of the following: If replacing the entire rail a. b. Remove the rail by loosening the screws attaching it to the PCBA. Ensure the replacement rail matches the original rail by checking the part number on the face of the rail. Upper and lower rails are not interchangeable. There are two different rail styles, depending on whether the PCBA has a single backplane connector or three separate ones. This information is also engraved on the face of the rail. Using the incorrect rail will be difficult to install and may damage the PCBA.
Note:
If replacing only the ejector a. Remove the rail from the PCBA. The ejector is retained by a spiral roll pin, which is pressed into the ejector. b. Support the bottom of the ejector on each side of the pin, and drive the pin out using a pin punch greater than 0.090 inches in diameter.
Replacement 1. 2. 3. 4. 5. Install the new ejector. Replace the PCBA. Replace the front EMI shield. Reset all circuit breakers. Replace the pocket module rear cover.
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5/15 Volt Power Supply

Use the following procedure to remove and replace the JPEG 5/15 volt power supply. Removal 1. 2. 3. 4. Turn off the power to the JPEG electronics gate by turning off the main and image circuit breakers located in the document processor main breaker box. Remove the pocket modules front and rear covers. Remove the rear EMI shield by loosening the thumbscrews and pulling the shield out. Disconnect the cables and harnesses listed in Table 4-7. Table 47. Cables and Harnesses to Disconnect from the PSU Cover Panel
Cable or Harness to Disconnect External POL External 24 VDC bias External CAR interface External DP interface External rear video External front video Internal POL Internal 24 VDC bias Internal CAR interface Internal DP interface AC safety ground J540 J541 J539 J538
Disconnect at
J1 of Video Interconnect PCBA J2 of Video Interconnect PCBA J540 J504 (backplane) J506 (backplane) J505 (backplane) JPEG frame
5. 6. 7. 8. 9.
Remove the AC line filter cover. Disconnect the AC line harness at the line filter. Remove the PSU cover panel. Remove the PSU control from J1 of the 5/15 power supply unit. Remove the 15 VDC fan power cable, the internal 15 VDC In, and internal VDC auxiliary cables from the V2 and V3 terminal strips of the 5/15 power supply unit.
10. Remove the internal AC connection and safety ground from the 5/15 power supply unit. 11. Disconnect the four 5 VDC cables from the DC bus bars. Ensure that there is enough slack in the cables to perform the rest of this procedure without interference. 12. Remove the upper 5/15 power supply unit restraining bracket.
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13. Tighten the screws that secure the four metal jumper straps to the terminals to prevent them from becoming loose and falling off. 14. Remove the 5/15 power supply unit. 15. Remove the PSU bus bar from the 5/15 power supply unit. Replacement 1. 2. 3. 4. 5. 6. Install the bus bars onto the 5/15 power supply unit loosely. Do not tighten the four nuts completely. Set the 5/15 power supply unit on the lower PSU mounting bracket with the terminals facing the rear of the gate. Position the 5/15 power supply unit so that the terminals are at the top of the supply as close to the backplane as possible. Attach the 5 VDC cables to the DC bus bars. Tighten the nuts that secure the DC bus bars completely. Use a digital ohmmeter to measure at least 0.5 ohms between the DC bus bars to ensure that no shorts exist between logic ground and 5 VDC, then disconnect the 5 VDC distribution cables. Install the upper 5/15 power supply unit restraining bracket. Reconnect the internal AC connection and safety ground to the 5/15 power supply unit. Reconnect the 15 VDC fan power cable, the internal 15 VDC In, and internal 15 VDC auxiliary cables to the V2 and V3 terminal strips of the 5/15 power supply unit.
7. 8. 9.
10. Reconnect the PSU control to J1 of the 5/15 power supply unit. 11. Reinstall the PSU cover panel. Ensure that all thumbscrews are installed to comply with EMI regulations. 12. Reconnect the cables and harnesses listed in Table 4-8 to the PSU cover panel. Table 48. Cables and Harnesses to Reconnect to the Internal PSU Cover Panel
Cable or Harness to Reconnect Internal POL Internal 24 VDC bias Internal CAR interface Internal DP interface J540 J541 J539 J538
Reconnect at
13. Reconnect the AC line harness to the PSU cover panel. 14. Attach the AC line filter cover. 15. Reconnect the external cables.
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16. Replace the rear and front EMI shields. Ensure that all thumbscrews are installed to comply with EMI regulations. 17. Replace the front and rear pocket module covers. 18. Reset all circuit breakers.
Fan Filter
The fan filter covers the rear of the JPEG electronics gate and can be washed, dried, and returned to service on site. If time is limited, remove the existing filter and replace it with a new one. Clean the dirty filter when more time is available. You can remove and replace the filter without shutting off power to the machine. Use the following procedure to remove and replace the JPEG fan filter. 1. 2. 3. Remove the pocket module rear cover. Press down on the top edge of the filter and pull the top edge of the filter out and up to clear the cover. Perform one of the following: Install a new filter. Clean the existing filter by rinsing it in warm water (mild soap or detergent may be used if the filter has become particularly dirty), and replace the filter after it has dried completely.
WARNING
Ensure that the filter is completely dry before reinserting it into the machine. Electrical shock could result from the combination of water in a high current environment.
Note:
At least one extra fan filter should be kept on site as a backup to when a dirty filter must be washed.
4.
Replace the pocket module cover.
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Fans
Use the following procedure to remove and replace any of the eight electronics gate fans. The fans are mounted in a common drawer assembly. Refer to Figure 4-22 for the location of the fans.
Figure 422. JPEG Fans Note: The JPEG electronics gate uses DC fans, which are not interchangeable with the fans used in the U4 electronics gate.
Removal
WARNING
Shut off electrical power to the document processor before proceeding with replacing the fans. Injury may result from electrical shock. The document processor is hard-wired to the facility power supply. Power must be shut off from the facility circuit breaker panel. Check to be sure power has been shut off to the document processor before proceeding.
1. 2. 3. 4. 5.
Turn off the power to the Imaging Module and document processor by turning off the main and image circuit breakers. Remove the pocket module rear cover. Remove the rear EMI shield by loosening the thumbscrews and pulling off the cover. Disconnect the fan drawer power connector and remove the drawer by pulling it straight back. Ensure that the harnesses and cables remain clear of the drawer. Unplug the faulty fan from the fan power PCBA, and remove it from the fan tray.
Replacement 1. Install the new fan, ensuring that the direction of flow (marked on the fan body) is upward, and plug it into the fan power PCBA.
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2. 3. 4. 5.
Restrain any excess wire length with a wire tie to prevent entry into the fan blades. Install the fan drawer. Replace the rear EMI shield. Replace the pocket module rear cover.
PCBAs
Use the following procedure to remove and replace a JPEG electronics gate PCBA. Refer to Figure 4-21 earlier in this section. Special Tools Antistatic wrist strap Static shielding bag
Removal 1. 2. 3. Turn off power to the JPEG electronics gate by turning off the main and image circuit breakers. Remove the pocket module front cover. Remove the front EMI shield by loosening the thumbscrews and pulling off the shield.
Caution
Use an antistatic wrist strap during this procedure to reduce the possibility of electrostatic discharge (ESD). Failure to wear one could result in equipment damage and/or performance degradation now or in the future.
4.
Locate the defective PCBA in the JPEG electronics gate, remove any cable that is attached to it, and remove the PCBA from the gate.
Replacement 1. 2. Remove the replacement PCBA from its static shielding bag. Ensure that the jumpers on the PCBA are set correctly. Refer to Table 4-9.
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Table 49. JPEG PCBA Jumper Setting
PCBA Main processor POL H1-H2 H1-H2 W2 W4 W9
Jumper Setting
W1 W3 W5 W11
3.
Perform one of the following: If you are replacing a DTI, POL, or main processor board a. b. c. Insert the PCBA into the slot and press the PCBA into the backplane, ensuring that it is firmly seated. Tighten the screws on the ejector handles. Replace the DTI and POL cables.
If you are replacing a PCBA from slots 00 through 08 or 18 through 28 a. b. c. Insert the PCBA into the slot with the ejector held parallel to the upper and lower card guides. Move the PCBA into the gate until the ejector (still held parallel to the card guides) prohibits further travel. Press slowly inward on the ejector so that the face of the ejector is against the back of the welded lip at the top and bottom of the gate. The lip to ejector interface acts as a fulcrum for the ejector (lever), which will engage the PCBAs into their sockets.
4. 5. 6. 7.
If the faulty PCBA was an image digitizer PCBA, run the calibration program. Refer to the IIPS Maintenance Manual, Volume 2.
Replace the front or rear internal video cables if they were disconnected. Reset all circuit breakers. Replace the front EMI shield. Ensure that all thumbscrews are tightened to comply with EMI regulations. Replace the pocket module front cover.
Clock PCBA
The clock PCBA is located beneath the air deflector plate in the front of the JPEG electronics gate. Use the following procedure to remove and replace the clock PCBA:
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1. 2.
Remove the air deflector plate from the front of the JPEG electronics gate. Remove the two screws securing the clock PCBA in place, and remove the PCBA.
Reverse this procedure to replace the clock PCBA.
Video Interconnect PCBA

Use the following procedure to remove and replace the video interconnect PCBA: 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove the front EMI cover of the pocket module housing the JPEG electronics gate. Disconnect all the cables attached to the power supply unit cover. Remove the AC line filter cover. Disconnect the AC line filter cable and safety ground. Remove the two video interface cable brackets from the power supply unit cover. Disconnect the external and internal video interface cables. Disconnect the internal POL cable to prevent it from breaking when removing the power supply unit cover. Remove the power supply unit cover. Remove the video interconnect PCBA.
Reverse this procedure to replace the video interconnect PCBA.
Lamp Controller/DTI Interface (LC/DTI I/F) PCBA

Use the following procedure to remove and replace the LC/DTI I/F PCBA: 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove the front EMI cover of the pocket module housing the JPEG electronics gate. Disconnect all the cables attached to the power supply unit cover. Remove the AC line filter cover. Disconnect the AC line filter cable and safety ground. Remove the two video interface cable brackets from the power supply unit cover. Disconnect the external and internal video interface cables. Disconnect the internal POL cable to prevent it from breaking when removing the power supply unit cover. Remove the power supply unit cover. Disconnect the internal and external lamp controller interface cables.
10. Remove the LC/DTI I/F PCBA. Reverse this procedure to replace the LC/DTI I/F PCBA.
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Imaging Module FRMs in the Document Processor

The following subsections provide procedures for removal and replacement of FRMs found in the document processor.
Image Button Light

Use the following procedure to remove and replace the image button light and its lamp. Removal
WARNING
1. 2.
Turn off the power to the IM and document processor by turning off the main and image circuit breakers. Grasp the image button light, and pull it straight out of the socket.
Caution
Do not use pliers to grasp the image button light. Damage to the light may result. Use an extractor (1992 0073) to grasp the light.
3.
Remove the lamp from the button light by pulling it straight out from the rear of the button light.
Replacement 1. 2. Place the new lamp into the image button light. Insert the image button light into the socket, and press it firmly in place.
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Image Circuit Breaker

Use the following procedure to remove and replace the image circuit breaker. Refer to Figure 4-23. Use the procedure under "Circuit Breakers" earlier in this section to remove and replace the imaging circuit breakers found on the IM. Removal
WARNING
Shut off electrical power to the document processor before proceeding with replacing the circuit breaker. Injury may result from electrical shock. The document processor is hard-wired to the facility power supply. Power must be shut off from the facility circuit breaker panel. Check to be sure power has been shut off before proceeding.
1. 2.
Turn off the power to the document processor by turning off the circuit breakers on the facility circuit breaker panel. Remove the document processor rear cover.
Figure 423. Image Circuit Breaker 3. 4. Remove six screws from the circuit breaker panel. Tilt the panel forward to expose the rear of the circuit breaker.
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5. 6. 7. 8.
Remove the four screws from the terminals on the rear of the breaker. Note to which terminal each wire attaches, and pull the wires free. Remove the four screws securing the circuit breaker to the panel. Remove the circuit breaker.
Replacement 1. 2. 3. 4. 5. 6. 7. Place the new circuit breaker into the panel from the rear. Attach the circuit breaker to the panel, using four screws. Attach each wire to the circuit breaker to the same terminal as on the old circuit breaker. Use screws to secure the wires to the terminals. Tilt the circuit breaker panel into the document processor frame, and secure it with six screws. Reset all circuit breakers. Replace the document processor rear cover. Turn on the facility power to the document processor.
Image Interface PCBA

Use the following procedure to remove and replace the image interface PCBA. Refer to Figure 4-24. Special Tools Anti-static wrist strap Static shielding bag
Removal
WARNING
1.
Turn off the power to the IM and document processor by turning off the main and image circuit breakers.
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Figure 424. Image Interface PCBA 2. 3. Remove the document processor rear cover. Use the wrist strap and ground it against the frame of the document processor to guard against the possibility of electrostatic discharge.
Caution
4. 5.
Remove the image interface PCBA from slot 15 of the document processor AA gate. Place the board in a static shielding bag.
Replacement 1. 2. 3. Place the image interface PCBA into slot 15 of the document processor AA gate. Replace the document processor rear cover. Reset all circuit breakers.
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Image Power Line Filter

Use the following procedure to remove and replace the power line filter: Removal
WARNING
Shut off electrical power to the document processor before proceeding with replacing the power line filter. Injury may result from electrical shock. The document processor is hard-wired to the facility power supply. Power must be shut off from the facility circuit breaker panel. Check to be sure power has been shut off to the document processor before proceeding.
1. 2. 3. 4. 5. 6. 7.
Turn off the power to the document processor by turning off the circuit breakers on the facility circuit breaker panel. Remove the document processor rear cover. Remove six screws from the circuit breaker panel. Tilt the panel forward. Remove the four hex nuts securing the power line filter to the document processor. Remove the power line filter. Disconnect the five power cables by removing the five hex nuts and pulling the terminals free.
Replacement 1. 2. 3. 4. 5. Connect the five power cables to the power line filter, using hex nuts. Attach the power line filter to the document processor, using hex nuts. Tilt the circuit breaker panel into the document processor frame, and secure it with six screws. Replace the document processor rear cover. Turn on the facility power to the document processor.
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Preventive Maintenance
This subsection includes discussions of both scheduled and unscheduled maintenance routines performed on the IM. The following FRMs are replaced at regular scheduled intervals, as indicated: Electronics gate cooling filter (replace every 500 hours) Lamp (replace every 2,000 hours)
A white reference tool must be used for calibration and white camera tests. This white tool has lines at the top, bottom, front, and back. Note: For details on calibration, refer to "Error Code Line Number 10300" in Section 6 of the Image Item Processing System Maintenance Manual.
Whenever you perform preventive maintenance, visually check for broken or worn parts: Check the braid strap at the cover hinges and between document processor frames for wear or a poor connection. Check all cables and harnesses for signs of damage or interference with the moving parts in the IM. Check to see that all connectors are secure. Check for debris that may have fallen into the IM or into the cooling air paths.
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Section 5 Maintaining the NDP 1000-4X/ NDP 1825-4X Imaging Module

This section provides detailed removal and replacement procedures used in Imaging Module (IM) maintenance. Procedures are described for the following items and activities: Front camera board/lens Calibrating the cameras Rear camera board/lens assembly Front camera head Rear camera head Thermal sensor Light sensor assembly (front or rear) Lamp socket assembly (front or rear) Lamp cover interlock switch Lamp control board Logic/lamp power supply Camera (linear) power supply (DP 1000 and DP 1800 front and rear) Backplane (DP 1000 and DP 1800) Power supply fan Logic gate fans Track components Beam of lights Bearing housing and shaft assembly Belts Cover interlock switch Crown roller assembly Camera frame and window assembly (front or rear)
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Maintaining the NDP 1000-4X/NDP 1825-4X Imaging Module
Idler assembly Front left idler pulley Track interlock switch and actuator
Front Camera Board/Lens Assembly

Use the following procedure to remove and replace the front camera board/lens assembly. Removal
WARNING
Be sure power is shut off to the dual IM before proceeding. Injury may result from electrical shock.
Caution
Handle fiber optic cables carefully when performing this procedure. Do not bend the cables sharply (more than 90 degrees) or place objects on the cables.
1. 2. 3.
Turn off the power to the dual IM and document processor by turning off the main and image circuit breakers. Remove the dual IM front and rear covers. Disconnect the camera head cable. See Figure 5-1.
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1 2 3 Camera head cable Screws above baseplate 4 5 Camera head ground strap Front camera board/lens assembly Screws (four, two above, two below)
Cap head screw (underneath baseplate) 6
Figure 51. Front Camera Board/Lens Assembly and Camera Head Cable (Overhead View) 4. 5. Unscrew the camera head ground strap from the baseplate. Unscrew the camera head from the baseplate by removing the cap head screw from underneath the baseplate (above the logic gate) and the two screws above the baseplate. Allow slack for the fiber optic cables underneath the camera by sliding the cables toward the camera assembly. Tilt the camera head assembly to unscrew the camera board/lens assembly from the camera head assembly by removing the four screws (two above and two below). Remove the camera board/lens assembly.
6. 7. 8.
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Replacement
Caution
Handle the fiber optic cables carefully. Do not bend the cables more than 90 degrees.
1. 2.
Transfer the camera ground strap to the new camera board/lens assembly. Reverse the steps in the removal procedure for the new camera board/lens assembly. Ensure that the fiber optic cables are close to the base plate but not touching or near the transport belts. Calibrate the camera using the calibration procedure next in this section.
3.
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Calibrating the Cameras

You must calibrate the cameras after removing/replacing the following: Front/rear camera board/lens assembly Front/rear camera head Front/rear light sensor assembly Front/rear lamp socket assembly Lamp control board Logic/lamp power supply Front/rear camera (linear) power supply (DP 1XXX, DP 1800)
Use this procedure to calibrate the cameras. Note: If you are running the Exerciser, you must close this program to calibrate the cameras.
1.
Start the Maintenance Test Routines (MTRs) by clicking on: DP1xxx --> CSE Utilities --> DP1xxx Maintenance Test Routines The MTR Test Description screen appears.
2. 3.
Select Dual Image Module Tests. Under Calibrate Scanner Tests, you can select one of the following: Calibrate Front Camera Calibrate Rear Camera
4. 5.
After making your selection, press the F10 screen or click on F10 to execute the test. Follow the prompts that appear on the screen. a. You are instructed to insert the black reference gauge (4335 7045-000) into the transport. The camera being calibrated must view the calibration gauge through its window assembly. If you are calibrating the front camera, place the calibration gauge in the rear window assembly slot. If you are calibrating the rear camera, the calibration gauge is placed in the front window assembly slot. Lift the Imaging Module cover and pull the appropiate camera frame and window assembly out. 1) Insert the tip of a pencil or pen into the square hole on the top of the assembly. See Figure 5-2.
Note:
b.
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1 2 Front camera frame and window assemblyinsert gauge here to calibrate rear camera Rear camera frame and window assemblyinsert gauge here to calibrate front camera
Figure 52. Inserting a Pen into the Top Hole of the Camera Frame and Window Assembly
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2) Pull the assembly up and out of the camera track. See Figure 5-3.
Figure 53. Pulling the Camera Frame and Window Assembly Out c. d. e. f. g. h. i. j. k. Insert the black reference gauge into the camera wall assembly. Close the Imaging Module cover and click on OK or press Enter. You are then prompted to insert the white reference gauge (4335 6930-000) into the transport. Lift the Imaging Module cover, remove the black reference gauge, and insert the white reference gauge into the camera wall assembly. Close the Imaging Module cover and click on OK or press Enter. Follow the prompts until the screen display shows calibration done. Remove the reference gauge from the transport. Slide the removed camera frame and window assembly into the camera wall. Close the Imaging Module cover.
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Rear Camera Board/Lens Assembly

Use the following procedure to remove and replace the rear camera board/lens assembly. Removal
WARNING
Caution
1. 2.
Turn off the power to the dual IM and document processor by turning off the main and image circuit breakers. Disconnect the camera head cable. See Figure 5-4.
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1 2 3 Camera head cable Idler roller assemblies Camera head ground strap 4 5 Rear camera board/lens assembly Screws (two on top and two on the bottom)
Figure 54. Rear Camera Head and Cable (Overhead View) 3. 4. 5. 6. 7. Remove the three idler roller assemblies by removing the nuts under the plate. Unscrew the camera head ground strap from the baseplate. Unscrew the camera board/lens assembly from the camera head assembly by removing the four screws. From the rear (with the cover closed), pull the camera board/lens assembly away from the camera head and rotate the board/lens assembly 45 degrees into the track wall. Open the cover and remove the camera board/lens assembly.
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Replacement
Caution
1. 2. 3.
Transfer the camera ground strap to the new camera board/lens assembly. Reverse the procedure in the preceding subsection for removing the camera board/lens assembly. Calibrate the camera. See Calibrating the Cameras earlier in this section.
Front Camera Head

Use the following procedure to remove and replace the front camera head. Removal
WARNING
Caution
1. 2. 3.
Turn off the power to the dual IM and document processor by turning off the main and image circuit breakers. Remove the dual IM front and rear covers. Disconnect these cables as follows: a. Disconnect the front camera head cable. See Figure 5-5.
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1 2 3 4 Front fiber optic cables Front camera head cable Front camera head Rear fiber optic cables
Figure 55. Front Camera Head, Cable, and Fiber Optic Cables (Overhead View - Fiber Optic Cable Covers Removed)
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b.
Disconnect the fiber optic cables: 1) Open the lamp cover. See Figure 5-6.
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1 2 Front fiber optic cable cover Lamp cover
Figure 56. Lamp Cover and Fiber Optic Cable Cover 2) Remove the fiber optic cable cover by removing one screw.
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Caution
When removing the light sensor assembly, do not loosen the nuts that hold the light sensors in place.
3) Remove the light sensor assemblies by removing two screws each. See Figure 5-7.
Legend
1 2 Front light sensor assemblies Screws
Figure 57. Front Light Sensor Assemblies
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4) Unplug the fiber optic cables from the lamp assembly. (See Figure 5-5.) 5) Loosen or remove the fiber optic cable tie wraps underneath the baseplate and remove the fiber optic cables from their routing. 4. 5. 6. Unscrew the camera head ground strap from the baseplate. Unscrew the camera head from the baseplate by removing the cap head screw from under the baseplate just above the logic gate and the two screws above the baseplate. Remove the camera.
Replacement
Caution
1. 2.
Reverse the steps in the removal procedure for the camera head. Ensure that the fiber optic cables are close to the baseplate but not touching or near the transport belts. Calibrate the camera. See Calibrating the Cameras earlier in this section.
Rear Camera Head

Use the following procedure to remove and replace the rear camera head. Removal
WARNING
Caution
1. 2.
Turn off the power to the dual IM and document processor by turning off the main and image circuit breakers. Remove the dual IM front and rear covers.
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3.
Use the following procedure to disconnect various cables: a. Disconnect the camera head cable. See Figure 5-8.
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1 2 3 4 Rear camera head cable Rear camera head Rear fiber optic cables Front fiber optic cables
Figure 58. Rear Camera Head and Cables (Overhead View - Fiber Optic Cable Covers Removed)
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b.
Disconnect the fiber optic cables as follows: 1) Open the lamp cover. See Figure 5-9.
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1 2 Rear fiber optic cable cover Lamp cover
Figure 59. Lamp Cover and Rear Fiber Optic Cable Cover
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Caution
When removing the light sensor assembly, do not loosen the nuts that hold the light sensors in place.
2) Remove the fiber optic cable cover by removing the screw. 3) Remove the light sensor assemblies by removing two screws each.
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1 2 Screws Rear light sensor assemblies
Figure 510. Rear Light Sensor Assemblies
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4) Unplug the fiber optic cables from the lamp assembly. 5) Loosen or remove the fiber cable tie wraps underneath the baseplate and remove the fiber optic cables from their routing. 4. Remove the top cover. a. b. c. d. e. f. 5. 6. 7. Remove the E rings from the cover pivot point. Remove the top cover ground strap from the right side of the cover. Close the top cover. Using a minimum of 4 tie wraps (3986 0663), tie the hanger spring to the baseplate through the hanger spring cutout. Open the top cover and remove the hinge pins. Lift the cover off the module.
Unscrew the camera head ground strap from the baseplate. Unscrew the camera head from the baseplate by removing the three screws above the baseplate. Remove the camera.
Replacement
Caution
1. 2.
Reverse the steps in the removal procedure for the camera head. Ensure that the fiber optic cables are close to the baseplate but are not touching or near the transport belts. Calibrate the camera. See Calibrating the Cameras earlier in this section.
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Thermal Sensor
Use this procedure to remove and replace the thermal sensor. Removal 1. Open the lamp cover. See Figure 5-11.
Legend
1 2 Thermal sensor Lamp cover
Figure 511. Lamp Cover and Thermal Sensor
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2. 3. 4.
Remove the two connector tabs from the sensor. Remove the two screws securing the thermal sensor bracket to the baseplate. Remove the thermal sensor from the bracket.
Replacement 1. Reverse the procedure in the preceding subsection for removing the sensor. Note: There is no polarity.
Light Sensor Assembly (Front or Rear)

Use this procedure to remove and replace the front or rear light sensor assembly. Removal 1. 2. 3. Remove the IM front cover. Disconnect the lamp monitor cable. Open the lamp cover. See Figure 5-12.
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1 2 3 Front fiber optic cable cover Rear fiber optic cable cover Lamp cover
Figure 512. Lamp Cover and Fiber Optic Cable Cover
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4. 5.
Remove the fiber optic cable cover. Remove the light sensor assembly connector. See Figure 5-13.
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1 2 Light sensor assembly connector Light sensor assembly connector nuts
Figure 513. Light Sensor Assembly Connector 6. 7. Loosen the nuts on the light sensor bodies. Remove the light sensor assembly.
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Replacement 1. Transfer all hardware to the new light sensor assembly. The clamp should be on the side of the bracket next to the body of the sensor. The washer, lockwasher, and nut should be assembled on the opposite side of the bracket. 2. Reverse the removal procedure in the preceding subsection. Note: Ensure that the top of the clamp is even with the top of the bracket. Make sure that the light sensor body is firmly seated at the bottom of the bracket slot when you are tightening the bracket.
3.
Calibrate the camera. See Calibrating the Cameras earlier in this section.
Lamp Socket Assembly (Front or Rear)

Use this procedure to replace the front or rear lamp socket assembly. Removal 1. 2. Remove the IM front cover. Open the lamp cover. See Figure 5-14.
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1 2 3 Harness and connector Lamp socket assemblies Lamp cover
Figure 514. Lamp Cover and Lamp Socket Assemblies
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3.
Disconnect the lamp power cable from the lamp assembly connector.
Caution
Handle the lamps at the lamp base. Do not touch the lamp reflector or lamp envelope and do not leave fingerprints on these areas.
4. 5. 6. 7.
Remove the two lamps from the assembly and set them aside. Remove the grommet from the baseplate. Remove the light sensor assembly connector from the baseplate using a small flathead screwdriver from above the assembly. See Figure 5-14 for a view of the connector. Remove the resistor bracket from the baseplate by removing the two screws from above the baseplate and the front and back. See Figure 5-15.
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1 2 Bracket Fan
Figure 515. Baseplate, Bracket, and Fan
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8. 9.
Remove the resistor cover from the resistor bracket by removing the one screw and nut. Remove the resistors from the resistor bracket by removing the four screws.
10. Remove the two resistor harness cable tie-downs from the resistor bracket. 11. Drop the lamp cooling fan to remove the lamp socket assembly. The nuts securing the fan are on studs underneath the baseplate to the left and right. (See Figure 5-13.) 12. Remove the lamp/optic mounting blocks by removing the two assemblies secured by two screws each from the baseplate. 13. Tilt the lamp/optic mounting blocks to remove the lamp socket assembly by removing the four screws from the lamp/optics mounting block. Replacement 1. 2. Transfer the grommet to the new lamp socket assembly. Reverse the removal procedure in the preceding subsection.
Caution
Handle the lamps by the lamp base when inserting them, holding them with a cloth if necessary. Do not touch the lamp reflector or lamp envelope and do not leave fingerprints on these areas.
3. 4.
Insert the lamps. Calibrate the camera. See Calibrating the Cameras earlier in this section.
Lamp Cover Interlock Switch

Use this procedure to remove and replace the lamp cover interlock switch. Removal 1. 2. Remove the IM front cover. Open the lamp cover. See Figure 5-16.
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1 2 Lamp cover interlock switch Lamp cover
Figure 516. Lamp Cover and Lamp Cover Interlock Switch 3. 4. 5. Remove the grommet. Unscrew the switch by removing the two screws. Slide the switch through the access hole.
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6.
Disconnect the switch cable from the resistor bracket. See Figure 5-17.
Legend
1 Bracket
Figure 517. Bracket 7. 8. 9. Remove the switch connector from the resistor bracket by removing the two connector tabs from the sensor. Remove the two screws securing the thermal sensor bracket to the baseplate. Remove the thermal sensor from the bracket.
Replacement 1. 2. 3. Transfer the grommet to the new switch. Reverse the removal operation in the preceding subsection. When mounting the switch, center the switch or visually align it with the magnet in the lamp cover. Test the interlock operation and adjust the switch position if necessary.
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Lamp Control Board

Use these procedures to remove and replace the lamp control board. Note: See Figures 2-44 and 2-45 in Section 2 of this guide for wiring block diagrams.
Removal 1. 2. Remove the IM front cover. Disconnect all five cables from the lamp control board. See Figure 5-18. Note: There are two duplicate connectors. Mark them if necessary so you do not reverse them when replacing the lamp control board.
Legend
1 Lamp control board
Figure 518. Lamp Control Board
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3.
Remove the lamp control board by removing the six screws that secure the board.
Replacement 1. 2. Reverse the lamp control board removal procedure in the preceding subsection. Ensure that the cables are properly connected. Calibrate both cameras. See Calibrating the Cameras earlier in this section.
Logic/Lamp Power Supply

Use these procedures to remove and replace the logic/lamp power supply. Removal 1. 2. Remove the IM front cover. Clip the cable ties from the right side of the logic/lamp power supply. See Figure 5-19.
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1 Logic/lamp power supply
Figure 519. Logic/Lamp Power Supply
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3.
Disconnect all cables from the logic/lamp supply except the AC cable. (See Figure 5-20 for connector identifications. See also Figures 2-44 and 2-45 in Section 2 of this guide for wiring block diagrams.)
Figure 520. Logic/Lamp Power Supply Connector Identification Note: 4. 5. 6. Remove the bus bar with a socket wrench.
Remove the logic/lamp power supply shelf assembly by removing the four screws. Pivot the shelf to remove the AC cable connections to the power supply. Remove the AC terminal block cover. Note: The oversized notches are on the wire side.
7. 8.
Remove the shelf and turn it upside down to expose the supply screws. Remove the supply from the shelf by removing the eight screws. Note: You must use the screws that are the same length when you reinstall the supply.
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Replacement 1. 2. Transfer the DC lamp control board harness to the new power supply. Reverse the steps in the removal procedure in the preceding subsection. Note: 3. 4. Ensure that the cables are properly connected. See Figure 5-18.
Perform a voltage adjustment here (if needed). Calibrate both cameras. See Calibrating the Cameras earlier in this section.
Camera (Linear) Power Supply (DP 1000, DP 1800 Front and Rear)
Notes:
The DP 1000 has one camera (linear) power supply. The DP 1800 has two camera (linear) power supplies.
Use this procedure to remove and replace the camera (linear) power supply. Removal 1. 2. Remove the dual IM front cover. Clip the cable ties from the right side of the logic/lamp power supply. See Figure 5-21.
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Legend
1 2 Linear power supply Logic/lamp power supply
Figure 521. Logic/Lamp Power Supply and Linear Power Supply 3. Disconnect all cables from the logic/lamp supply except the AC cable. Note: 4. 5. Remove the bus bar with a socket wrench.
Remove the logic/lamp power supply shelf assembly by removing the four screws. Remove the logic/lamp power supply and set it aside.
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6. 7. 8. 9.
Disconnect the camera (linear) power supply DC connector from the backplane. Disconnect the AC harness. It is routed through a hole in the tray. Cut the cable ties holding the AC harness. Remove the power supply as follows, depending on the sorter: For the DP 1000, remove two screws. For the DP 1800, remove three nuts. If you remove the DP 1800 rear camera power supply, you may have to remove the DP 1800 front camera power supply.
Note:
Replacement 1. 2. 3. Reverse the steps in the removal procedure in the preceding subsection. Use new cable ties to secure cables that were previously tied down. Perform a voltage adjustment, if needed. Calibrate both cameras. See Calibrating the Cameras earlier in this section.
Backplane (DP 1000 and DP 1800)

Use this procedure to remove and replace the backplanes. Removal 1. 2. Remove the front and rear dual IM covers. Disconnect all cables from the backplane. See Figure 5-22 for the backplane location.
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Legend
1 Backplane
Figure 522. Backplane
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See Figures 5-23 and 5-24 for backplane connector locations. Note: See Figures 2-44 and 2-45 in Section 2 of this guide for wiring block diagrams.
J544
JA C 620 JB B 520
JB 541 JB 540
JS 541 3J
JB F 520 JS 540 JF 540 4J 1J 7J JF 610 8J JA F 520 JF 513 JX 513
5J
2J
JB 610
JS 610
JB C 620 J511
6J
9 60 4
Figure 523. DP 1000 Backplane Connectors
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JA B 620
J544
JA F 620
JB 541 JB 531 JB 601 J520
JF 541 JF 531 JF 601
JP 14
JB 600
JP 13
JF 600
JB B 620 JB 530 J511
JB F 620 JF 530 JF 513 JX 513
8 60 4
Figure 524. DP 1825 Backplane Connectors 3. 4. Remove the harness support bracket from the backplane/card cage by removing the 4 screws. Remove the cable ties and fan connector (for the DP 1000, one connector, for the DP 1800, two connectors) from the right side of backplane (when viewed at the cage from the rear of the machine). Remove the card cage cover by removing 22 screws on the DP 1000 and 28 screws on the DP 1800. Remove the card cage by removing the four screws. Remove the backplane by removing 18 screws on the DP 1000 and 24 screws on the DP 1800.
5. 6. 7.
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Replacement 1. 2. Install the new backplane using two boards at either end of the card cage to assist with alignment. Install all screws except those screws that hold the harness support. Reverse the remaining steps in the removal procedure in the preceding subsection.
Power Supply Fan

Use these procedures to remove and replace the power supply fan. Removal 1. 2. 3. Remove the dual IM front cover. Clip the cable ties from the right side of the logic/lamp power supply. (See Logic/Lamp Power Supply earlier in this section.) Disconnect all cables from the logic/lamp supply except the AC cable. Note: 4. 5. 6. Remove the bus bar with a socket wrench.
Remove the logic/lamp power supply shelf assembly by removing the four screws. Remove the logic/lamp supply and set it aside. For the DP 1800 only, remove the camera (linear) rear power supply as described earlier in this section in Camera (Linear) Power Supply (DP 1000, DP 1800 Front and Rear). Disconnect the fan ground and two power connections. Remove the fan by removing the two screws at the top and the bottom.
7. 8.
Replacement 1. Reverse the steps in the removal procedure in the preceding subsection.
Logic Gate Fans

Use these procedures to remove and replace the logic gate fans. Removal 1. 2. 3. Remove the rear dual IM cover. Disconnect the AC fan connector(s) (one connector on the DP 1000 and two on the DP 1800). Remove the fan tray by removing the one screw. See Figure 5-25.
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1 2 Screw Fan tray
Figure 525. Logic Gate Fans 4. Disconnect the fan power from the harness.
Replacement 1. Reverse the steps in the removal procedure in the preceding subsection.
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Track Components
Use the following subsections to remove and replace dual IM components that are part of the document transport. Figure 5-26 shows the location of track components.
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1 2 3 4 5 6 7 Tensioner Bearing housing and shaft assembly Tensioner Timing belt Transport flat belt Tensioner Drive belt 8 9 Front left idler pulley Tensioner
10 Tensioner 11 Transport flat belt 12 Drive belt 13 Transport flat belt
Figure 526. Track Components
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Beam of Lights
Use the following procedure to remove and replace the beam of lights. The beam of lights are composed of two pieces, a photo-transistor that attaches to the rear track wall and a light emitting diode (LED) that attaches to the front track wall. Both pieces are shipped together and should be installed as a set. Removal 1. 2. 3. Turn off the power to the dual IM and document processor by turning off the main and image circuit breakers. Open the dual IM top cover. Unplug the beam of light pair. See Figure 5-27.
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1 Beam of light pairs
Figure 527. Beam of Light Pairs 4. 5. 6. Remove the nut securing each piece. Remove the wire (if present) from the clips securing it to the base plate. Remove each piece.
Replacement 1. 2. Place the LED into the square socket in the front track wall. Secure the LED with the nut.
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3. 4. 5. 6. 7. 8. 9.
Plug the LED into its associated connector. Place the photo-transistor into the round socket in the rear track wall. Secure the photo-transistor with the nut. Plug the photo-transistor into its associated connector. Secure the wire (if present) in the clips on the base plate. Adjust the photo-transistor, using T&A 2974 3333 found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." Close the dual IM top cover.
Bearing Housing and Shaft Assembly

Use the following procedure to remove and replace the bearing housing and shaft assembly. Removal
WARNING
1. 2. 3. 4.
Turn off the power to the dual IM and document processor by turning off the main and image circuit breakers. Open the dual IM top cover. Remove the rear covers to the dual IM and the first pocket module. Remove the flat belt above the base plate that touches the drive pulley. Refer to the procedure in the "Belts" subsection later in this section, and see Figure 5-28.
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1 2 3 Bearing housing and shaft assembly Transport flat belt Drive belt
Figure 528. Bearing Housing and Shaft Assembly and Belts 5. 6. 7. 8. 9. Remove the nut securing the drive pulley to the assembly. Use a wrench on the flats on the bottom of the shaft to prevent the shaft from turning while removing the nut. Remove the drive pulley. Be sure to save the key. Remove the timing belts. Refer to the "Belts" subsection later in this section. Remove the three screws securing the assembly to the base plate. Remove the bearing housing and shaft assembly.
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10. Remove the pulleys and spacers from the assembly and save them for replacement. Note in which order they are assembled. Replacement 1. 2. 3. 4. 5. Attach the pulleys and spacers to the bearing housing and shaft assembly in the order in which they were disassembled. Attach the bearing housing and shaft assembly to the base plate, using three screws. Assemble the top pulley and key onto the shaft. Attach the drive pulley to the assembly, using a nut. Replace the belts, and adjust them according to the following T&As found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." 6. 7. For timing belts, use T&A 3304 2078. For transport belts, use T&A 3304 4124. For drive belts, use T&A 3304 4793.
Replace the rear covers to the dual IM and the second pocket module. Close the dual IM top cover.
Belts
Use the following procedure to remove and replace a belt. Refer to Figure 5-29 for belt, idler, and tensioner locations. Removal 1. 2. 3. Open or remove the appropriate cover to expose the belt. Loosen the appropriate tensioner. Remove the belt.
Replacement 1. Install the belt around the crown roller or pulley. Ensure that the belt is seated properly. See Figure 5-29.
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Legend
Figure 529. Belt, Idler, and Tensioner Locations 2. Adjust the belt according to the following T&As found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." 3. For the timing belt, use T&A 3304 2078. For transport flat belts, use T&A 3304 4124. For the drive belts, use T&A 3304 4793.
Reset all circuit breakers.
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4.
Close or replace the cover.
Cover Interlock Switch

Use the following procedure to remove and replace the cover interlock switch. Removal 1. 2. 3. 4. Turn off the power to the image gate by turning off the power switch on the document processor panel. Open the dual IM top cover. Disconnect the wire to the switch. Squeeze each end of the switch, and pull it straight up to remove.
Replacement 1. 2. 3. 4. Set the switch into the socket, and push it in to lock. Connect the wire to the switch by pushing the connector on the terminal. Adjust the switch, using T&A 2974 3614 found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." Close the dual IM top cover.
Crown Roller Assembly

Use the following procedure to remove and replace a crown roller assembly. Removal 1. 2. 3. Turn off the power to the image gate by turning off the power switch on the document processor panel. Open the dual IM top cover. Remove the belt that touches the crown roller. Refer to the belt removal procedure earlier in this section and see Figure 5-30.
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1 2 Transport flat belt Crown roller
Figure 530. Crown Roller Assembly and Belts 4. Perform the following steps if the crown roller is located along the track: a. b. 5. 6. Loosen the track wall by loosening the hex head screws. Move the track wall aside so that the crown roller clears the wall.
Use a screwdriver to remove the e-ring from the top of the crown roller assembly. Pull up on the crown roller assembly to remove. Note the placement of the washers and the crown roller.
Replacement 1. 2. Place the washers and crown roller on the shaft in the same order as removed. Snap the e-ring into place over the shaft to secure the crown roller assembly.
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3. 4. 5.
Adjust the track wall, using T&As 3304 4082 and 3304 4108 found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." Replace the belt and adjust it, using T&A 3304 4124 found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." Close the dual IM top cover.
Idler Assembly
Use one of the following procedures to remove and replace an idler assembly. Refer to Figure 5-31 for idler assembly and tensioner locations.
Front Left Idler Pulley

Use the following procedure to remove and replace the front left idler pulley. Removal 1. 2. Open the dual IM top cover. Remove the dual IM front cover, filler panel, rear cover, and the microfilmer rear cover. Loosen the lock nut on the top of the belt tensioner. Refer to Figure 5-31 for the associated tensioner.
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Legend
Figure 531. Front Left Idler Pulley and Belt and Tensioner Locations 3. 4. 5. 6. 7. 8. Loosen the post on the belt tensioner to loosen it from the t-nut. Remove the microfilm drive belt. Remove the lock nut from the idler pulley. Loosen the post on the idler pulley. Slide the idler to the right, and remove the other drive belt. Remove the t-nut from the idler assembly.
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9.
Remove the idler assembly.
10. Remove the bearing and pulley assembly by removing the arc clip and spacer and pulling the assembly off the shaft. Replacement 1. 2. 3. 4. 5. 6. Place the bearing and pulley assembly on the shaft, and secure it with an arc clip and spacer. Attach the shaft and idler pulley assembly to the base plate, using a t-nut. Do not tighten the nut. Replace the belts around the idler pulleys and tensioner. Replace the lock nut on the idler pulley. Do not tighten the nut. Adjust the belts according to T&A 3304 4793 found in Appendix A, "Tests and Adjustments and Special Engineering Instructions." Close the dual IM top cover. Replace the dual IM front cover, filler panel, rear cover, and the microfilmer rear cover.
Track Interlock Switch and Actuator

Use the following procedure to remove and replace one or both of the track interlock switches and/or their actuators. Removal 1. 2. 3. 4. 5. 6. 7. Turn off the power to the image gate by turning off the power switch on the document processor panel. Open the dual IM top cover. Remove the two hex head screws securing the switch bracket to the base plate. Remove the bracket. Disconnect the wires to the switch by pulling the connector off the terminals. Note to which terminals the wires connect. Remove the two screws securing the switch and its actuator to the bracket. Remove the switch and actuator.
Replacement 1. 2. 3. 4. 5. Attach the switch and its actuator to the bracket, using two screws. Be sure that the actuator is placed between the switch and bracket. Connect the wires to the switch by pushing the connectors on the terminals. Be sure to connect the wires to the same terminals from which they were removed. Attach the bracket to the base plate, using hex head screws. Adjust the switch, using T&A 3304 4116 found in Appendix A, "Special Engineering Instructions and Tests and Adjustments." Close the dual IM top cover.
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551
552
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Appendix A Special Engineering Instructions and Tests and Adjustments

This appendix provides the special engineering instructions (SEIs) and tests and adjustments (T&As) for the imaging module. These documents appear in this appendix in the order shown in Table A-1. Table A1. Imaging Module SEIs and T&As
Document Title Area 1 Microfilm and Image Panel Hinge Lubrication Checking Procedure for Transmissive BOLs Cleaning of Beam of Lights (BOLs) Cover Interlock Switch Filler Panel Adjustment Star Washer Use in Electrical Connections Top Cover and Carriage Plate Adjustment Timing Belt Tension Rear Wall Adjustment Traverse Plate Adjustment Front Wall Adjustment Interlock Switch and Bracket Adjustment Transport Belt Tension Adjustment DP 1800 DL1 Image Camera Assembly Rear Optical Gate Wall Adjustment Imaging Module to Microfilm Drive Belt Tension Panel Trim Installation TDC Microfilm Trim Plate Instructions U4 and JPEG Microfilm Air Inlet Hose Relocation SEI SEI T&A T&A SEI SEI T&A T&A T&A T&A T&A T&A T&A T&A T&A T&A SEI SEI SEI
Type
Part Number 2103 2081 2974 3333 2974 3028 2974 3614 2974 4919 3304 0536 3304 2060 3304 2078 3304 4082 3304 4090 3304 4108 3304 4116 3304 4124 3304 4512 3304 4785 3304 4793 3304 4801 3304 4827 3304 5097
continued
2983 7986204
A1
Special Engineering Instructions and Tests and Adjustments
Table A1. Imaging Module SEIs and T&As (cont.)
Document Title U4 and JPEG CSE Maintenance Procedure Shutter Adjust U4 Power On Check List Camera Inspection and Cleaning Procedure Image Aux. Motor/Belt Tension Adj. Tightening the Lamp Power Supply Terminals Fiber Bundle Repair Procedure DP1825 EMI/ESD/Safety Feature NDP EMI/ESD/Safety Feature JPEG Image Power-On Checklist Microfilm Installation with Dual Image Dual Image Power On Checklist SEI T&A SEI SEI T&A SEI SEI SEI SEI SEI SEI SEI
Type
Part Number 3304 5204 3304 5261 3304 5402 3304 5782 3304 5253 3304 5485 3304 5790 3304 6343 2493 6296 4326 1379 4331 4095 4344 6798
A2
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4331 4095 Microfilm Installation with Dual Image
A146
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A147
Glossary
A
Area 1 The principal module of the DP 1XXX document processor. Most of the operator activities occur at this machine location.
B
beam of light (BOL) An infrared sensing device placed at intervals along the document path to monitor the documents during flow. This device gives information to the document processor concerning such conditions as document alignment and document progress along the track. See also document detector. BOL See beam of light.
C
camera submodule The components that make up the imaging camera that is part of an IC 1800-J or an 1825-J Imaging Module. CAR See courtesy amount read (CAR) module. CCITT See Consultative Committee on International Telephone and Telegraph. Consultative Committee on International Telephone and Telegraph (CCITT) (1) Committee that defines standard compression algorithms. (2) An algorithm defined by this committee. cinemode microfilmer An optional module that films both sides of documents at full transport speed, including microfilm header numbers, document identification numbers, and image count marks. client service engineer (CSE) A Unisys engineer with specialized training to provide field service and maintenance to Unisys computer hardware and software.
2983 7986203
Glossary1
Glossary
courtesy amount read (CAR) module A device that uses document images to locate, analyze, and interpret handwritten or machine-printed numeric courtesy amounts on financial documents. CSE See client service engineer.
D
DL1 Abbreviation for design level 1. A version of the DP Document Processor. DL2 Abbreviation for design level 2. A version of the DP document processor. DL3 A version of the NDP Document Processor. This Design Level numbering system continues the numbering system used by the DP 1XXX Document Processor. document detector An infrared sensing device placed at intervals along the document path to monitor the documents during flow. This device gives information to the DP 1XXX Document Processors concerning such conditions as document alignment and document progress along the track. document processor A machine that reads document code lines and sorts documents into pockets. Document processors optionally endorse, microfilm, or image documents. DP 1XXX Document Processor In IIPS, a high-speed document processor used to image and sort documents.
E
electromagnetic interferance (EMI) A high frequency energy generated as a byproduct of electronic device activities. This type of energy must be isolated and controlled from injection into the electrical power lines. Limits are specified by the Federal Communications Commission and by foreign regulatory agencies. electronics gate submodule The electronic components that support imaging for an IC 1800-J or an 1825-J imaging module and are located in the basic 8-pocket module of the DP 1800 Document Processor. See also Imaging Module. EMI See electromagnetic interference.
Glossary2
2983 7986203
Glossary
F
fiber optic bundles Bundles of optical fiber that convert a round spot of light into a rectangular bar of light to illuminate documents for imaging. fiber optic link A communication pathway using optical fiber as the transmission media. field replacement module (FRM) The unit designated as the least possible part that the CSE can use to repair the equipment. frame and window assembly An assembly in the NDP 1000-4X/NDP 1825-4X Imaging Module that holds the window through which the image of the document is captured. FRM See field replacement module.
H
host The mainframe computer in IIPS that makes general purpose processing, storage, and communications resources available to image application and system programs and centralizes the monitoring of the system. The host is the same host used with Unisys document processors. host processor A processor that accommodates the needs of a peripheral device such as a document processor.
I
IC 1000-J Imaging Module See Imaging Module. IC 1825-J Imaging Module See Imaging Module. IIPS See Image Item Processing System. IM See Imaging Module. image digitizer (1) The digital representation of one side of a document. (2) To form a digital representation of a document.
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Glossary3
Glossary
Image Item Processing System (IIPS) A Unisys product for capturing, storing, and retrieving document images. The product is a platform for imaging applications, such as the Image Check Processing System that facilitates financial document processing. image pipeline The set of printed wiring circuit boards in the IC 1XXX Imaging Module used to process and compress image data. There are two pipelines in the system, one for front document image capture and another for rear document image capture. Any of the intelligent terminals in IIPS networked to a storage and retrieval module. Imaging Module A part of the DP 1000 and DP 1825 document processors (IC 1000/IC 1825) or both DP document processors and NDP 1150 and NDP 1825 document processors (NDP 1000-4X/NDP 1825-4X) that captures and digitizes check images. IC 1XXX Imaging Module (IM) A part of the document processor that captures and digitizes check images. It consists of two submodules: the camera submodule and the electronics gate submodule. See also camera submodule, electronics gate submodule. IWS See image workstation.
J
joint photographic experts group (JPEG) The International Standards Organization (ISO)/Consultative Committee on International Telephone and Telegraph (CCITT) standard for compressing images. JPEG See joint photographic experts group.
N
NDP See Network Document Processor. Network Document Processor (NDP) The new Unisys document processor that succeeds the DP 1825 and DP 1000 Document Processors. The NDP reads document MICR code lines and sorts documents. NDPs may also endorse, microfilm, or capture images of documents. The NDP connects to an industry-standard IEEE 802.3 LAN and runs under the Windows NT operating system.
Glossary4
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Glossary
O
optical gate A transparent section of the track wall through which documents are imaged. optical gate walls The front optical gate wall and the rear optical gate wall that holds the windows through which the front and rear images of the documents are captured. optical towers The front optical tower and the rear optical tower that holds the optical elements that direct images to the electronics of the camera submodule.
P
PCBA Acronym for printed circuit board assembly. POC See power on confidence test. power on confidence test (POC) An automatic test of the equipment that checks all the components to verify that they are in proper operating condition. printed circuit board assembly (PCBA) A thin insulating board used to mount and connect various electronic components and microchips in a pattern of conductive lines. This circuit pattern is etched into the board's surface. programmable read-only memory (PROM) A permanent memory chip that is programmed after manufacturing. PROM See programmable read-only memory.
R
reject An item sent to the reject pocket by the document processor. reject pocket The pocket to which items are sent that fail the sort pattern or are involved in feeder exceptions. The reject pocket is the first pocket in the first pocket module. Items specifically selected to the reject pocket by the sort pattern may also be directed to the reject pocket. resequencer A PCBA in the image station.
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Glossary5
Glossary
S
SCSI See small-computer systems interface. Small-Computer Systems Interface (SCSI) A parallel, bidirectional communications interface defined by the ANSI X3.131-1986 standard and used to transfer data between digital interfaces. SRM See storage and retrieval module. storage and retrieval module (SRM) A unit in IIPS that stores image packets on magnetic disk and sends images to image workstations for display or printing.
T
track release levers Levers located near the front walls of the imaging module that, when turned, open and close the imaging module document track. transmit (Xmit) The keyboard key designated to transmit data.
X
Xmit The keyboard key that, when pressed, transmits data. On the NDP, the "-" key on the numeric keypad functions as the Xmit key. See transmit.
Glossary6
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Index
A
air hose, microfilmer relocation, 2-16 area 1, top cover trim installing, 2-25 assembly, crown roller,removal and replacement procedures, IC 1000/IC 1825, 4-38 NDP 1000-4X/NDP 1825-4X, 5-47 assembly, front frame and window removal and replacement procedures, IC 1000/IC 1825, 4-39 assembly, idler, removal and replacement procedures IC 1000/IC 1825, 4-40 NDP 1000-4X/NDP 1825-4X, 5-49 assembly, lamp socket (front/rear), NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-23 assembly, lens, NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-2, 5-8 assembly, light sensor (front/rear), NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-20 assembly, rear frame and window removal and replacement procedures, IC 1000/IC 1825, 4-42 assembly, reject pocket installing, 2-24 beam of lights, NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-42 bearing housing and shaft assembly, IC 1000/IC 1825 removal and replacement procedures, 4-36 bearing housing and shaft assembly, NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-43 belts, IC 1000/IC 1825 removal and replacement procedures, 4-37 belts, NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-45 board, front camera, NDP 1000-4X/ NDP 1825-4X, removal and replacement procedures, 5-2 board, lamp control, NDP 1000-4X/ NDP 1825-4X, removal and replacement procedures, 5-29 board, rear camera, NDP 1000-4X/ NDP 1825-4X, removal and replacement procedures, 5-8
C
cable CAR data , connecting, 2-81 document processor interface, connecting, 2-55, 2-78 five-volt power supply ground, connecting, 2-56 image lift power, connecting, 2-58 lamp controller interface, connecting, 2-76 lamp controller power, connecting, 2-76 lamp power supply interface, connecting, 2-63 logic ground, connecting, 2-80 POL fiber optic, connecting, 2-80 cables 5-volt power supply, connecting, 2-60 dual IM interface, installing, 2-82 external JPEG image, connecting, 2-75
B
backplane, removal and replacement procedures IC 1000/IC 1825, 4-44 NDP 1000-4X/NDP 1825-4X, 5-35 backplane, JPEG, IC 1000/IC 1825 removal and replacement procedures, 4-58 beam of lights, IC 1000/IC 1825 removal and replacement procedures, 4-34
2983 7986203
Index1
Index
cables, JPEG image gate, removal and replacement procedures, IC 1000/IC 1825, 4-60 cables, U4 image cables connecting, 2-51 cables, U4 image gate, removal and replacement procedures, IC 1000/IC 1825, 4-47 cables, video connecting, 2-61, 2-81 calibrating cameras, NDP 1000-4X/ NDP 1825-4X, 5-5 camera removal and replacement procedures, IC 1000//C 1825, 4-19 camera (linear) power supply, NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-33 camera board, front, NDP 1000-4X/ NDP 1825-4X, removal and replacement procedures, 5-2 camera board, rear, NDP 1000-4X/ NDP 1825-4X, removal and replacement procedures, 5-8 camera box, IC 1000/IC 1825 removal and replacement procedures, 4-9 camera head, front, NDP 1000-4X/ NDP 1825-4X, removal and replacement procedures, 5-10 camera head, rear, NDP 1000-4X/ NDP 1825-4X, removal and replacement procedures, 5-14 cameras, calibrating, NDP 1000-4X/ NDP 1825-4X, 5-5 CAR data cable connecting, 2-81 CCITT, 0-1 installing, 2-64 check out dual IM, 2-89 IM, 2-88 cinemode microfilmer, location of, 1-1 circuit breaker document processor upgrade, 2-2 circuit breaker with dual IM installing, 2-36 circuit breakers, IC 1000/IC 1825 removal and replacement procedures, 4-13 clock PCBA, JPEG electronics gate, IC 1000/IC 1825 removal and replacement procedures, 4-70 components microfilmer drive transfer, installing, 2-15 Index2
ICS, installing, 2-87 track, NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-41 connecting 15-volt camera harness, 2-78 15-volt harness, 2-59 24-volt bias harness, 2-54 24-volt sense harness, 2-79 5-volt DC sense harness, 2-57 5-volt power supply cables, 2-60 5-volt power supply ground cable, 2-56 CAR data cable, 2-81 document processor interface cable, 2-55, 2-78 external JPEG image cables, 2-75 IM fan harness, 2-53 image lift power cable, 2-58 lamp controller interface cable, 2-76 lamp controller power cable, 2-76 lamp power supply interface cable, 2-63 logic ground cable, 2-80 POL fiber optic cable, 2-80 secondary AC harness, 2-51 secondary AC supply harness, 2-76 U4 image cables, 2-51 15-volt harness, 2-59 24-volt bias harness, 2-54 5-volt DC sense harness, 2-57 5-volt power supply cables, 2-60 5-volt power supply ground cable, 2-56 document processor interface cable, 2-55 IM fan harness, 2-53 image lift power cable, 2-58 lamp power supply interface cable, 2-63 secondary AC harness, 2-51 video cables, 2-61 video cables, 2-61, 2-81 cooling change installation NDP 1000-4X/NDP 1825-4X, 2-20 cover interlock switch, removal and replacement procedures IC 1000/IC 1825, 4-38 NDP 1000-4X/NDP 1825-4X, 5-47 crown roller assembly, removal and replacement procedures IC 1000/IC 1825, 4-38 NDP 1000-4X/NDP 1825-4X, 5-47
D
document processor 2983 7986203
Index
preparing, 2-7 document processor interface cable connecting, 2-55, 2-78 document processor interface harnesses (with dual IM) installing, 2-32 document processor interface harnesses (with IM) installing, 2-27 drive, (no microfilmer) installing, 2-17 drive, TDC microfilmer installing, 2-16 drive, Unisys microfilmer installing, 2-16 dual IM check out, 2-89 dual IM interface cables installing, 2-82 dual IM power up, 2-89
E
enclosure removal and replacement procedures, IC 1000/IC 1825, 4-22 energy dump fan, IC 1000/IC 1825 removal and replacement procedures, 4-14
F
fan, IM, cooling removal and replacement procedures, IC 1000/IC 1825, 4-21 fan, lamp cooling removal and replacement procedures, IC 1000/IC 1825, 4-27 fan, power supply, NDP 1000-4X/ NDP 1825-4X, removal and replacement procedures, 5-39 fans, logic gate, NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-39 field replacement modules IC 1000/IC 1825, 4-2 IC 1000/IC 1825 Imaging Module document processor, 4-3 electronics gate, 4-3 removal and replacement procedures, 4-4 filter, image power line, IC 1000/IC 1825 2983 7986203
removal and replacement procedures, 4-76 five-volt DC sense harness connecting, 2-57 five-volt power supply ground cable connecting, 2-56 FRMs 15-volt power supply, IC 1000/IC 1825 removal and replacement procedures, 4-15 backplane, IC 1000/IC 1825 removal and replacement procedures, 4-44 backplane, JPEG, IC 1000/IC 1825 removal and replacement procedures, 4-58 beam of lights, IC 1000/IC 1825 removal and replacement procedures, 4-34 bearing housing and shaft assembly, IC 1000/IC 1825 removal and replacement procedures, 4-36 belts, IC 1000/IC 1825 removal and replacement procedures, 4-37 camera box, IC 1000/IC 1825 removal and replacement procedures, 4-9 circuit breakers, IC 1000/IC 1825 removal and replacement procedures, 4-13 cover interlock switch, IC 1000/IC 1825 removal and replacement procedures, 4-38 crown roller assembly, IC 1000/IC 1825 removal and replacement procedures, 4-38 document processor, 4-3 electronics gate, 4-3 energy dump fan, IC 1000/IC 1825 removal and replacement procedures, 4-14 front frame and window assembly, IC 1000/IC 1825 removal and replacement procedures, 4-39 front left idler pulley, IC 1000/IC 1825 removal and replacement procedures, 4-40 front right idler pulley, IC 1000/IC 1825 removal and replacement procedures, 4-41 harnesses Index3
Index
removal and replacement procedures, 4-4, 4-6 IC 1000/IC 1825, 4-2 IC 1000/IC 1825 Imaging Module document processor, 4-3 electronics gate, 4-3 removal and replacement procedures, 4-4 idler assembly, IC 1000/IC 1825 removal and replacement procedures, 4-40 IM cooling fan, IC 1000/IC 1825 removal and replacement procedures, 4-21 image button light, IC 1000/IC 1825 removal and replacement procedures, 4-72 image camera PCBA assemblies, IC 1000/IC 1825 removal and replacement procedures, 4-19 image circuit breaker, IC 1000/IC 1825 removal and replacement procedures, 4-73 image interface PCBA, IC 1000/IC 1825 removal and replacement procedures, 4-74 image power line filter, IC 1000/IC 1825 removal and replacement procedures, 4-76 Imaging Module, in document processor, IC 1000/IC 1825 removal and replacement procedures, 4-72 JPEG 5/15-volt power supply, IC 1000 /IC 1825 removal and replacement procedures, 4-65 JPEG cables removal and replacement procedures, 4-6 JPEG card guide, IC 1000/IC 1825 removal and replacement procedures, 4-61 JPEG ejector, IC 1000/IC 1825 removal and replacement procedures, 4-63 JPEG electronics gate clock PCBA, IC 1000/IC 1825 removal and replacement procedures, 4-70 JPEG electronics gate fans, IC 1000/ IC 1825 Index4
removal and replacement procedures, 4-68 JPEG electronics gate lamp controller/DTI interface PCBA, IC 1000/IC 1825 removal and replacement procedures, 4-71 JPEG electronics gate LC/DTI I/F PCBA, IC 1000/IC 1825 removal and replacement procedures, 4-71 JPEG electronics gate PCBAs, IC 1000/ IC 1825 removal and replacement procedures, 4-69 JPEG electronics gate video interconnect PCBA, IC 1000/IC 1825 removal and replacement procedures, 4-71 JPEG electronics gate, IC 1000/IC 1825 removal and replacement procedures, 4-58 JPEG fan filter, IC 1000/IC 1825 removal and replacement procedures, 4-67 JPEG image gate cables and harnesses, IC 1000/IC 1825 removal and replacement procedures, 4-60 lamp and enclosure, IC 1000/IC 1825 removal and replacement procedures, 4-22 lamp control PCBA, IC 1000/IC 1825 removal and replacement procedures, 4-25 lamp cooling fan, IC 1000/IC 1825 removal and replacement procedures, 4-27 lamp power supply, IC 1000/IC 1825 removal and replacement procedures, 4-29 power control PCBA, IC 1000/IC 1825 removal and replacement procedures, 4-32 rear frame and window assembly, IC 1000/IC 1825 removal and replacement procedures, 4-42 removal and replacement procedures, 4-4 shutter sensor and actuator, IC 1000/ IC 1825 removal and replacement procedures, 4-33 track components, IC 1000/IC 1825 2983 7986203
Index
removal and replacement procedures, 4-34 track interlock switch and actuator, IC 1000/IC 1825 removal and replacement procedures, 4-43 U4 5-volt power supply, IC 1000/IC 1825 removal and replacement procedures, 4-50 U4 cables removal and replacement procedures, 4-4 U4 card guide, IC 1000/IC 1825 removal and replacement procedures, 4-48 U4 ejector, IC 1000/IC 1825 removal and replacement procedures, 4-49 U4 electronics gate fans, IC 1000/IC 1825 removal and replacement procedures, 4-53 U4 electronics gate PCBAs, IC 1000/ IC 1825 removal and replacement procedures, 4-55 U4 electronics gate, IC 1000/IC 1825 removal and replacement procedures, 4-44 U4 fan filter, IC 1000/IC 1825 removal and replacement procedures, 4-52 U4 image gate cables and harnesses, IC 1000/IC 1825 removal and replacement procedures, 4-47 front frame and window assembly, IC 1000/ IC 1825 removal and replacement procedures, 4-39 front left idler pulley, IC 1000/IC 1825 removal and replacement procedures, 4-40 front right idler pulley, IC 1000/IC 1825 removal and replacement procedures, 4-41
H
harness 15-volt, connecting, 2-59 15-volt camera, connecting, 2-78 24-volt bias, connecting, 2-54 24-volt sense, connecting, 2-79 five-volt DC sense, connecting, 2-57 IM fan, connecting, 2-53 secondary AC, connecting, 2-51 secondary AC supply, connecting, 2-76 harnesses removal and replacement procedures, 4-4, 4-6 harnesses, JPEG image gate, removal and replacement procedures, IC 1000/IC 1825, 4-60 harnesses, U4 image gate, removal and replacement procedures, IC 1000/IC 1825, 4-47 harnesses, with dual IM installing, 2-32 harnesses, with IM installing, 2-27 head, front camera, NDP 1000-4X/ NDP 1825-4X, removal and replacement procedures, 5-10 head, rear camera, NDP 1000-4X/ NDP 1825-4X, removal and replacement procedures, 5-14 hose, air, microfilmer relocation, 2-16 HSPE, top cover trim installing, 2-26
I
IC 1000-J Imaging Module, 1-1 IC 1825-J Imaging Module, 1-1 ICS components installing, 2-87 idler assembly, IC 1000/IC 1825 removal and replacement procedures, 4-40 idler assembly, NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-49 idler pulley, front left, NDP 1000-4X/ NDP 1825-4X, removal and replacement procedures, 5-49 IM check out, 2-88 IM cooling fan, IC 1000/IC 1825 Index5
G
gate PCBAs, U4 installing, 2-41, 2-49, 2-64
2983 7986203
Index
removal and replacement procedures, 4-21 IM fan harness connecting, 2-53 IM power up, 2-88 image button light, IC 1000/IC 1825 removal and replacement procedures, 4-72 image camera PCBA assemblies, IC 1000/ IC 1825 removal and replacement procedures, 4-19 image circuit breaker, IC 1000/IC 1825 removal and replacement procedures, 4-73 image lift power cable connecting, 2-58 Imaging Module components, in document processor, IC 1000/IC 1825 removal and replacement procedures, 4-72 Imaging Module installing, 2-10 unpacking, 2-6 Imaging Module installation, 2-1 installation cooling change NDP 1000-4X/NDP 1825-4X, 2-20 Imaging Module, 2-1 installing CCITT electronics gate, 2-64 circuit breaker with dual IM, 2-36 document processor interface harnesses with dual IM, 2-32 document processor interface harnesses with IM, 2-27 drive - no microfilmer, 2-17 drive - TDC microfilmer, 2-16 drive - Unisys microfilmer, 2-16 dual IM interface cables, 2-82 ICS components, 2-87 Imaging Module, 2-10 JPEG electronics gate, 2-64 logic (with dual IM), 2-32 logic with IM, 2-27 microfilmer drive transfer components, 2-15 PCBAs, U4 electronics gate, 2-49 reject pocket assembly, 2-24 top cover trim, 2-25 top cover trim, area 1, 2-25 top cover trim, HSPE, 2-26 top cover trim, NIE, 2-25 top cover trim, TDC microfilmer, 2-26 top cover trim, Unisys microfilmer, 2-26 U4 electronics gate, 2-41 U4 electronics gate PCBAs, 2-49
J
JPEG 5/15-volt power supply, IC 1000/IC 1825 removal and replacement procedures, 4-65 JPEG cables removal and replacement procedures, 4-6 JPEG card guide, IC 1000/IC 1825 removal and replacement procedures, 4-61 JPEG ejector, IC 1000/IC 1825 removal and replacement procedures, 4-63 installing, 2-64 JPEG electronics gate fans, IC 1000/IC 1825 removal and replacement procedures, 4-68 JPEG electronics gate, IC 1000/IC 1825 removal and replacement procedures, 4-58 JPEG fan filter, IC 1000/IC 1825 removal and replacement procedures, 4-67 JPEG image cables connecting, 2-75 JPEG image gate cables and harnesses removal and replacement procedures, IC 1000/IC 1825, 4-60 JPEG image gate cables and harnesses IC 1000/IC 1825 removal and replacement procedures, 4-60
L
lamp removal and replacement procedures, IC 1000/IC 1825, 4-22 lamp and enclosure, IC 1000/IC 1825 removal and replacement procedures, 4-22 lamp control board, NDP 1000-4X/ NDP 1825-4X, removal and replacement procedures, 5-29 lamp control PCBA, IC 1000/IC 1825 removal and replacement procedures, 4-25 lamp controller interface cable connecting, 2-76 lamp controller power cable connecting, 2-76 lamp controller/DTI interface PCBA, JPEG electronics gate, IC 1000/IC 1825 removal and replacement procedures, 4-71 lamp cooling fan, IC 1000/IC 1825 removal and replacement procedures, 4-27 lamp cover interlock switch, NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-26 lamp power supply interface cable 2983 7986203
Index6
Index
connecting, 2-63 lamp power supply, IC 1000/IC 1825 removal and replacement procedures, 4-29 lamp socket assembly (front/rear), NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-23 lamp socket assembly, (front/rear), NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-23 LC/DTI I/F PCBA, JPEG electronics gate, IC 1000/IC 1825 removal and replacement procedures, 4-71 lens assembly, NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-2, 5-8 leveling the machine, 2-13 leveling the modules, 2-13 light sensor assembly (front/rear), NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-20 logic gate fans, NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-39 logic ground cable connecting, 2-80 logic, with dual IM installing, 2-32 logic, with IM installing, 2-27 logic/lamp power supply, NDP 1000-4X/ NDP 1825-4X, removal and replacement procedures, 5-30
M
machine leveling, 2-13 maintenance NDP 1000-4X/NDP 1825-4X, 5-1 backplane (DP 1XXX), 5-35 beam of lights, 5-42 bearing housing and shaft assembly, 5-43 belts, 5-45 calibrating cameras, 5-5 camera (linear) power supply, 5-33 cover interlock switch, 5-47 crown roller assembly, 5-47 front camera board/lens assembly, 5-2 front camera head, 5-10 idler assembly, 5-49 idler pulley, front left, 5-49 2983 7986203
lamp control board, 5-29 lamp cover interlock switch, 5-26 lamp socket assembly (front/rear), 5-23 light sensor assembly (front/rear), 5-20 logic gate fans, 5-39 logic/lamp power supply, 5-30 power supply fan, 5-39 rear camera board/lens assembly, 5-8 rear camera head, 5-14 thermal sensor, 5-19 track components, 5-41 track interlock switch and actuator, 5-51 NDP 1000-4X/NDP 1825-4X removal and replacement procedures, 5-1 backplane (DP 1XXX), 5-35 beam of lights, 5-42 bearing housing and shaft assembly, 5-43 belts, 5-45 calibrating cameras, 5-5 camera (linear) power supply, 5-33 cover interlock switch, 5-47 crown roller assembly, 5-47 front camera board/lens assembly, 5-2 front camera head, 5-10 idler assembly, 5-49 idler pulley, front left, 5-49 lamp control board, 5-29 lamp cover interlock switch, 5-26 lamp socket assembly (front/rear), 5-23 light sensor assembly (front/rear), 5-20 logic gate fans, 5-39 logic/lamp power supply, 5-30 power supply fan, 5-39 rear camera board/lens assembly, 5-8 rear camera head, 5-14 thermal sensor, 5-19 track comonents, 5-41 track interlock switch and actuator, 5-51 maintenance philosophy IC 1000/IC 1825, 4-1 maintenance procedure IC 1000/IC 1825, 4-1 maintenance, preventive, IC 1000/ IC 1825, 4-77 microfilmer (none), drive installing, 2-17 microfilmer air hose relocation, 2-16 microfilmer drive transfer components installing, 2-15 microfilmer drive, TDC installing, 2-16 microfilmer drive, Unisys Index7
Index
installing, 2-16 microfilmer, location of, 1-1 microfilmer, TDC, top cover trim installing, 2-26 microfilmer, Unisys, top cover trim installing, 2-26 modules field replacement IC 1000/IC 1825 Imaging Module document processor, 4-3 electronics gate, 4-3 removal and replacement procedures, 4-4 IC 1000/IC 1825 field replacement, 4-2 leveling, 2-13
N
NDP 1000-4X/NDP 1825-4X cooling change installation, 2-20 installation cooling change, 2-20 NIE, top cover trim installing, 2-25
P
PCBA, image interface, IC 1000/IC 1825 removal and replacement procedures, 4-74 PCBA, lamp control removal and replacement procedures, IC 1000/IC 1825, 4-25 PCBA, power control removal and replacement procedures, IC 1000/IC 1825, 4-32 PCBAs, JPEG electronics gate, IC 1000/ IC 1825 removal and replacement procedures, 4-69 PCBAs, U4 electronics gate installing, 2-49 PCBAs, U4 electronics gate, IC 1000/IC 1825 removal and replacement procedures, 4-55 pocket assembly, reject installing, 2-24 pocket module location of, 1-1 POL fiber optic cable connecting, 2-80 power control PCBA, IC 1000/IC 1825 removal and replacement procedures, 4-32 Index8
power supply fan, NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-39 power supply, 15-volt, IC 1000/IC 1825 removal and replacement procedures, 4-15 power supply, camera (linear), NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-33 power supply, JPEG 5/15-volt, IC 1000/IC 1825 removal and replacement procedures, 4-65 power supply, lamp removal and replacement procedures, IC 1000/IC 1825, 4-29 power supply, logic/lamp, NDP 1000-4X/ NDP 1825-4X, removal and replacement procedures, 5-30 power supply, U4 5-volt, IC 1000/IC 1825 removal and replacement procedures, 4-50 power up dual IM, 2-89 IM, 2-88 preparing document processor, 2-7 preventive maintenance, IC 1000/IC 1825, 4-77 procedure IC 1000/IC 1825 maintenance, 4-1 procedures removal and replacement, backplane (DP 1XXX), 5-35 removal and replacement, NDP 1000-4X/NDP 1825-4X, 5-1 beam of lights, 5-42 bearing housing and shaft assembly, 5-43 belts, 5-45 calibrating cameras, 5-5 camera (linear) power supply, 5-33 cover interlock switch, 5-47 crown roller assembly, 5-47 front camera board/lens assembly, 5-2 front camera head, 5-10 idler assembly, 5-49 idler pulley, front left, 5-49 lamp control board, 5-29 lamp cover interlock switch, 5-26 lamp socket assembly (front/rear), 5-23 light sensor assembly (front/rear), 5-20 logic gate fans, 5-39 logic/lamp power supply, 5-30 power supply fan, 5-39 rear camera board/lens assembly, 5-8 rear camera head, 5-14 thermal sensor, 5-19 track components, 5-41 2983 7986203
Index
track interlock switch and actuator, 5-51 pulley, front left idler removal and replacement procedures, IC 1000/IC 1825, 4-40 pulley, front right idler removal and replacement procedures, IC 1000/IC 1825, 4-41 pulley, idler, front left, NDP 1000-4X/ NDP 1825-4X, removal and replacement procedures, 5-49
R
rear frame and window assembly, IC 1000/ IC 1825 removal and replacement procedures, 4-42 reject pocket assembly installing, 2-24 relocation microfilmer air hose, 2-16 removal and replacement procedures, 4-4 15-volt power supply, IC 1000/IC 1825, 4-15 backplane, IC 1000/IC 1825, 4-44 backplane, JPEG, IC 1000/IC 1825, 4-58 beam of lights, IC 1000/IC 1825, 4-34 bearing housing and shaft assembly, IC 1000/IC 1825, 4-36 belts, IC 1000/IC 1825, 4-37 camera box, IC 1000/IC 1825, 4-9 circuit breakers, IC 1000/IC 1825, 4-13 clock PCBA, JPEG electronics gate, IC 1000/IC 1825, 4-70 cover interlock switch, IC 1000/ IC 1825, 4-38 crown roller assembly, IC 1000/ IC 1825, 4-38 energy dump fan, IC 1000/IC 1825, 4-14 filter, image power line, IC 1000/ IC 1825, 4-76 front frame and window assembly, IC 1000/IC 1825, 4-39 front left idler pulley, IC 1000/IC 1825, 4-40 front right idler pulley, IC 1000/ IC 1825, 4-41 harnesses, 4-4, 4-6 idler assembly, IC 1000/IC 1825, 4-40 IM cooling fan, IC 1000/IC 1825, 4-21 image camera PCBA assemblies, IC 1000/IC 1825, 4-19 image circuit breaker, IC 1000/IC 1825, 4-73 imaging button light, IC 1000/IC 1825, 4-72 2983 7986203
Imaging Module components, in document processor, IC 1000/IC 1825, 4-72 JPEG 5/15-volt power supply, IC 1000/ IC 1825, 4-65 JPEG cables, 4-6 JPEG card guide, IC 1000/IC 1825, 4-61 JPEG ejector, IC 1000/IC 1825, 4-63 JPEG electronics gate fans, IC 1000/ IC 1825, 4-68 JPEG electronics gate, IC 1000/ IC 1825, 4-58 JPEG fan filter, IC 1000/IC 1825, 4-67 JPEG image gate cables and harnesses, IC 1000/IC 1825, 4-60 lamp and enclosure, IC 1000/IC 1825, 4-22 lamp control PCBA, IC 1000/IC 1825, 4-25 lamp controller/DTI interface PCBA, JPEG electronics gate, IC 1000/ IC 1825, 4-71 lamp cooling fan, IC 1000/IC 1825, 4-27 lamp power supply, IC 1000/IC 1825, 4-29 LC/DTI I/F PCBA, JPEG electronics gate, IC 1000/IC 1825, 4-71 PCBA, image interface, IC 1000/ IC 1825, 4-74 PCBAs, JPEG electronics gate, IC 1000/ IC 1825, 4-69 PCBAs, U4 electronics gate, IC 1000/ IC 1825, 4-55 power control PCBA, IC 1000/IC 1825, 4-32 rear frame and window assembly, IC 1000/IC 1825, 4-42 shutter sensor and actuator, IC 1000/ IC 1825, 4-33 track components, IC 1000/IC 1825, 4-34 track interlock switch and actuator, IC 1000/IC 1825, 4-43 U4 5-volt power supply, IC 1000/ IC 1825, 4-50 U4 cables, 4-4 U4 card guide, IC 1000/IC 1825, 4-48 U4 ejector, IC 1000/IC 1825, 4-49 U4 electronics gate fans, IC 1000/ IC 1825, 4-53 U4 electronics gate, IC 1000/IC 1825, 4-44 U4 fan filter, IC 1000/IC 1825, 4-52 U4 image gate cables and harnesses, IC 1000/IC 1825, 4-47 video interconnect PCBA, JPEG electronics gate, IC 1000/ IC 1825, 4-71 removal and replacement procedures, NDP 1000-4X/NDP 1825-4X, 5-1 Index9
Index
backplane (DP 1XXX), 5-35 beam of lights, 5-42 bearing housing and shaft assembly, 5-43 belts, 5-45 calibrating cameras, 5-5 camera (linear) power supply, 5-33 cover interlock switch, 5-47 crown roller assembly, 5-47 front camera board/lens assembly, 5-2 front camera head, 5-10 idler assembly, 5-49 idler pulley, front left, 5-49 lamp control board, 5-29 lamp cover interlock switch, 5-26 lamp socket assembly (front/rear), 5-23 light sensor assembly (front/rear), 5-20 logic gate fans, 5-39 logic/lamp power supply, 5-30 power supply fan, 5-39 rear camera board/lens assembly, 5-8 rear camera head, 5-14 thermal sensor, 5-19 track components, 5-41 track interlock switch and actuator, 5-51 roller assembly, crown removal and replacement procedures, IC 1000/IC 1825, 4-38
switch, track interlock and actuator removal and replacement procedures, IC 1000/IC 1825, 4-43 switch, track interlock, and actuator, NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-51
T
TDC microfilmer drive installing, 2-16 thermal sensor, NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-19 top cover trim installing, 2-25 top cover trim, area 1 installing, 2-25 top cover trim, HSPE installing, 2-26 top cover trim, NIE installing, 2-25 top cover trim, TDC microfilmer installing, 2-26 top cover trim, Unisys microfilmer installing, 2-26 track components, IC 1000/IC 1825 removal and replacement procedures, 4-34 track components, NDP 1000-4X/ NDP 1825-4X, removal and replacement procedures, 5-41 track interlock switch and actuator, IC 1000/IC 1825 removal and replacement procedures, 4-43 track interlock switch and actuator, NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-51 trim, area 1 installing, 2-25 trim, HSPE installing, 2-26 trim, microfilmer, TDC installing, 2-26 trim, microfilmer, Unisys installing, 2-26 trim, NIE installing, 2-25 trim, top cover installing, 2-25
S
secondary AC harness connecting, 2-51 secondary AC supply harness connecting, 2-76 sensor assembly, light (front/rear), NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-20 sensor, thermal, NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-19 shutter sensor and actuator, IC 1000/IC 1825 removal and replacement procedures, 4-33 switch, cover interlock removal and replacement procedures, IC 1000/IC 1825, 4-38 switch, cover interlock, NDP 1000-4X/ NDP 1825-4X, removal and replacement procedures, 5-47 switch, lamp cover interlock, NDP 1000-4X/NDP 1825-4X, removal and replacement procedures, 5-26 Index10
2983 7986203
Index
U
U4 5-volt power supply, IC 1000/IC 1825 removal and replacement procedures, 4-50 U4 cables removal and replacement procedures, 4-4 U4 card guide, IC 1000/IC 1825 removal and replacement procedures, 4-48 U4 ejector, IC 1000/IC 1825 removal and replacement procedures, 4-49 installing, 2-41 U4 electronics gate fans, IC 1000/IC 1825 removal and replacement procedures, 4-53 U4 electronics gate PCBAs installing, 2-49 U4 electronics gate, IC 1000/IC 1825 removal and replacement procedures, 4-44 U4 fan filter, IC 1000/IC 1825 removal and replacement procedures, 4-52 U4 image cables connecting, 2-51 U4 image cables, 15-volt harness connecting, 2-59 U4 image cables, 24-volt bias harness connecting, 2-54 U4 image cables, 5-volt DC sense harness connecting, 2-57 U4 image cables, 5-volt power supply cables connecting, 2-60 U4 image cables, 5-volt power supply ground cable connecting, 2-56 U4 image cables, document processor interface cable connecting, 2-55 U4 image cables, IM fan harness connecting, 2-53 U4 image cables, image power lift cable connecting, 2-58 U4 image cables, lamp power supply interface cable connecting, 2-63 U4 image cables, secondary AC harness connecting, 2-51 U4 image cables, video cables connecting, 2-61 U4 image gate cables and harnesses removal and replacement procedures, IC 1000/IC 1825, 4-47 Unisys microfilmer drive installing, 2-16 2983 7986203
unpacking Imaging Module, 2-6 upgrade document processor circuit breaker, 2-2
V
video cables connecting, 2-61, 2-81 video interconnect PCBA, JPEG electronics gate, IC 1000/IC 1825 removal and replacement procedures, 4-71
1
15-volt camera harness connecting, 2-78 15-volt harness connecting, 2-59 15-volt power supply, IC 1000/IC 1825 removal and replacement procedures, 4-15
2
24-volt bias harness connecting, 2-54 24-volt sense harness connecting, 2-79
5
5-volt power supply cables connecting, 2-60
Index11

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IC 1000/IC 1825 and NDP 1000-4X/NDP18254X Imaging Module

Release: Date: December 1998 Part number: 2983 7986204

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IC 1000/IC 1825 AND NDP 1000-4X/NDP18254X IMAGING MODULE

Installation and Servicing Guide

December 1998 Printed in USA 2983 7986204

IC 1000/IC 1825 AND NDP 1000-4X/NDP18254X IMAGING MODULE

Installation and Servicing Guide

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Imaging Module Installation on a Document Processor

Unisys Proprietary - Class B

IC 1000/IC 1825 Imaging Module Components

Unisys Proprietary - Class B

Maintaining the IC 1000/IC 1825 Imaging Module

Unisys Proprietary - Class B

Maintaining the NDP 1000-4X/ NDP 1825-4X Imaging Module

Unisys Proprietary - Class B

Unisys Proprietary - Class B

53 56 57 59 511 512 513 515 516

Unisys Proprietary - Class B

Unisys Proprietary - Class B

Unisys Proprietary - Class B

Unisys Proprietary - Class B

Unisys Proprietary - Class B

About This Guide

Unisys Proprietary - Class B

About This Guide

Unisys Proprietary - Class B

About This Guide

Related Product Information

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About This Guide

Unisys Proprietary - Class B

About This Guide

Unisys Proprietary - Class B

Section 1 Operation and Components

IC 1000/IC 1825 Imaging Module

Unisys Proprietary - Class B

Operation and Components

Imaging Module Interfaces

Unisys Proprietary - Class B

Operation and Components

Figure 12. Imaging Module System Interfaces

Unisys Proprietary - Class B

Operation and Components

Imaging Module Components

Unisys Proprietary - Class B

Operation and Components

NDP 1000-4X/NDP 1825-4X Imaging Module

Unisys Proprietary - Class B

Operation and Components

Imaging Module Components

Unisys Proprietary - Class B

Operation and Components

Image Module Interfaces

Unisys Proprietary - Class B

Section 2 Imaging Module Installation on a Document Processor

Unisys Proprietary - Class B

Imaging Module Installation on a Document Processor