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TAbLE OF CONTENTS - Neopost Technologies Ltd

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5. LTC ANTI WTdss 88 08I dod FINGOW PNV dX3 NYO dX3 YWO 85 TAWO cct TAWO szc ca3aoouva vet TAGODuvVE S08 08T god 4 1 3a3023vg 18 134 189 Q3u T8Z C8TI ZL T10S 097 081 097 08T TEL C8T vOL 6LT E SW LHM 13A 9S C8T 18 Q3u Cardfolder III Service Manual Issue 2 Dec 2012 Page 5 10 100 140 CARDFOLDER III SERVICE MANUAL L peus 600z 81 JSquusAON Kopseupam ejoq 0991 206 JequinN lu uuinooq iv 925 LNA 60333 ONISIM TI 401040 smi SNolAddd SNINOO l vesg9s cgl 2 13A v6 08L Ti v aay AYOSNAS ASIJ YOLOW OV 5 z ma 1865 c68l l Hj one
6. X e gt lt ul Z Om gt N n Ps aS st ERAN E lt Gs am lt po R5 2 FE lt lt OG Os co lt G 2E 5 HOr c 4 4 Chassis Assembly A2 1406 A Output Cardfolder III Service Manual Issue 2 Dec 2012 Page 4 9 Item Part No 1 117 240 2 169 112 3 169 115 4 179 109 179 110 6 182 443 7 182 444 8 B2 1539 A 9 B2 1540 A 10 C5 1141 A 11 C5 1143 A 12 C6385A 13 C8 0217 A 14 C9640A 15 D1040A 16 E0367A i7 E1061A 18 E1078A 19 E5005A 20 E5071A 21 E5074A 22 E5098A 23 F1366A 24 F1 0451 A 25 F1 0453 A 26 F4134A 27 GO167P 28 G1008C 29 G1136A 30 G6 0249 A 31 P2437A 32 B9164A 33 G6002A 34 G4092A Fixings 50 E2505A 51 E2826A 52 E2830A 53 E4033A 54 E5073A 9100130B 9100456R 9100459U 9108382X 9108383Y 9101013W 9101014X 9105489 9110686X 9103641J 9103789N 9103826B 9103835L 9104089A 9104133W 9104135Y 9104147L 9106676V 9110687Y 9110688Z 9104390P 9105216 91046110 9104659G 9100524D 9110689A 9104868M 9104827U 100 140 CARDFOLDER Description OPTO PAIR LONG RANGE P CLIP 1 4 RIVET 5mm 2 5 3 5 GRIP CLUTCH EC30LL CW 8mm 24V CLUTCH EC30LL CCW 8mm24V LOOM EMITTER 300 XH LOOM RECEIVER W A 300 XH CASSETTE FEED LOWER CASSETTE FEED UPPPER SHAFT CASSETTE FEED PIVOT SHAFT CASSETTE DRIVE PRESSURE PAD FOLD ROLLER COATED INDEXING SENSOR BAR T BEARING 8mm SQ
7. H N O O Page 3 25 9104695G 9105602B 9105590P 9104868M 9110524D G1136A G1184A G1185A G6002A G6 0249 A 100 140 CARDFOLDER III SERVICE MANUAL SPRING OMR SHAFT SPRING LATCH RH SPRING LATCH LH WASHER CASSETTE FEED GUIDE Cardfolder 2 Upgrade Spares N H HN To upgrade an esisting set of Cardfolder 2 spares only the folowing parts need be ordered A full set of upgrade spares can be obtained by ordering part number 9110526F A0 0595 A SAP No 9100302F 9108382X 9108383Y 9100807G 9100751Y 9100753A 9110527G 9101014X 9101087Y 9110518X 9110519Y 9110520Z 9103613E 9105793A 9103789N 9103826B 9103835L 9104072H 9104121 9104124M 9104142F 9110006P 9112448H 9110521A 9106545 9104430F 9104440R 91105228 9110523C 9104505 9104644D 9105602B 9105590P 9104868M 9110524D Page 3 26 NTL No 131 824 179 109 179 110 181 128 180 769 180 776 181 1670 182 444 182 693 184 2351 C7 0445 A C8 0213 A D0044A E0291A E0367A E1061A E1078A E4033A E5050A E5054A E5086A E5126A F4 0322 A F4 0308 A F4266A F5002A F5012A F5 0173 A F5050A F5125A G1060A G1184A G1185A G6002A G6 0249 A Description SWITCH MAGNET SMALL CLUTCH EC30LL CW 8mm 24V CLUTCH EC30LL CCW 8mm24V CLUTCH LENZE PSI 04 24V PCB ASSY AM4 STEPPER PCB WIDEBODY DISK SENSOR MTR W D 179 1000 STEPPER LOOM RECEIVER W A 300 XH OPB715 WIRED SENSOR 2x3W CARDFOLDER3 PSU ASSY 26V FOLD BLADE FOLD ROLL
8. mr rw Rus 5 6 5 4 Cardfolder Interface PCB 180 789 Circuit Diagram 5 7 5 5 Long Range Sensor PCB 180 790 Circuit Diagram 5 7 5 6 Cardfolder I F PCB 180 8436 Circuit 5 8 5 7 Cardfolder PSU 184 2351 Wiring Diagram 5 9 5 8 Cardfolder Barcode Interface Wiring Diagram 5 10 5 9 Machine Wiring 809 nnnm mmm nnn 5 11 Issue 2 Jan 2011 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL Section 1 Unpacking and Installation Sect 1 1 1 2 1 2 1 1 2 2 1 2 3 1 2 4 Safety Notes Installation Connecting the Stands Attachment of Cardfolder Electrical Connections Attachment of Card Processor Cardfolder III Service Manual Page 1 2 1 4 1 4 1 4 1 6 Issue 1 Nov 2010 Page 1 1 100 140 CARDFOLDER III SERVICE MANUAL 1 Upacking amp Installation 1 1 Safety Notes Warning Do not work inside the ma chine unless you are a trained mechanic or electrician Stop the machine and discon nect the power cord before you open the machine Only a trained electrician should work with the electrical parts A voltage of 120 Volts may be present inside this machine The power source can produce enough voltage and current to be lethal Warning This machine is equipped with a three pronged plug One of the prongs on the plug provides a
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10. O O O ti Fig 2 The CF infeed consists of a conveyor amongst which there are 2 sensors the first be ing the hopper sensor reflective the second the deskew sensor The conveyor is driven direct from the main drive and runs constantly whilst the drive is on 2 2 2 Infeed Operation A document detected at the hopper sensor will set the machine to start the process If the system is in the non running Waiting for Prime state then it will run up the drive at this point The document will be transferred along the conveyor to block the deskew sensor and continue to the input rollers of Fold 1 where it will be held for the deskew period timed from blocking the sensor This position can also act as a hold point should there be a hold up upstream Whilst a document is on the conveyor the system will be sending a busy signal to the feed machine which inhibits further items being sent If all is clear upstream after the deskew period the document is ready to enter the Fold 1 sub module Cardfolder III Service Manual Issue 1 Nov 2010 Page 2 3 100 140 CARDFOLDER III SERVICE MANUAL 2 2 3 Fold 1 Description The fold 1 sub module consists of a pivoting fold plate assembly on which are mount ed two spring loaded fold rollers in the central position constantly driven by a gear on the fold 1
11. H 8d ov 5 y l q31243 3311 d amp s es 3GZd3 soe 9 n vas MIO Ld3 v yoce LM TOS Ln GNOW Ob al 6 6 99 ODA B 99 AYIH AN 138 Avay YOLON 9 OLON SOLON 0 c GNO c 0 GNO YMd1 lt MS PZ z MSAFE z MSAPZ MS vZ 1 li MSAFE MSATZ 36 AQZ Lie O O Mdh 99 SMdT QNS puoog aeddeis Z poog 9 vt ONO ee N 7 ano ee INS 3 ONO el ONO vw006 Zl 0 ONO ONO 6z ONO ez oz Md ez HMd yz iz oz oz MMd oz Md vz ez 5 pg e108 SAM zz 1 5 108 z 9 oz N9 6 6 54 3 8 91 1SSd g1 1554 MeSd G Addold 659 Old YeSd Add d 7 1154 7 1154 6d L Sd 5 0 xals 0 5 144 6 19S 6 198 9 an Q 3n 031193 n L 031 NOS 9 yds 9 vas 125 G 105 G 155 N3ld3 amd YMd ldi dd c Yia YI 419513 z d3lS z 43115 99 99 929 99 LOLr 180 8436 ircuit Diagram 5 6 Cardfolder I F PCB C Issue 1 Nov 2010 Cardfolder III Service Manual Page 5 8 100 140 CARDFOLDER III SERVICE MANUAL weibeig BULIM TSEC PS8T NSd III J9pjojple9 Z S 1d e U
12. IN THE EVENT OF ANY EMERGEN CY OR TO STOP THE MACHINE FOR ANY OTHER REASON OPEN ANY COVER Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL Important ELECTRICAL INSTALLATION NOTES THESE NOTES MUST BE READ PRIOR TO INSTALLING THIS MACHINE This equipment is supplied with an unterminated three core lead for connection to the mains supply The connection must only be made by a qualified electrician or by a qualified Service Engineer 1 This equipment must be earthed 2 For continued protection against the risk of fire fuses must only be replaced by those of the same type and rating 3 Caution This equipment is internally fused in both Live and Neutral leads 4 Maximum input current is xA for 115V and 6 3A for 230V Maximum leak age current shall not exceed 5 of the input current 5 Euro and US Can Where the plug is fitted the socket outlet shall be in stalled near the equipment and shall be easily accessible 230 Volt Machines Wire Colours Live Brown Neutral Blue Earth Green Yellow 115 Volt Machines Wire Colours Live Brown Neutral Blue Earth Green Yellow Caution High leakage current An earth connection is essential before connecting to the supply Cardfolder III Service Manual Issue 1 Nov 2010 Page 1 3 100 140 CARDFOLDER III SERVICE MANUAL 1 2 Installation The Cardfolder is attached to the inserter by means of a location spigot and 2 M5 cap head screws on each side
13. 3831 4391040459 65854 US Su0 1HM 18 X18 1HM 340 q38 1HM TA T3A 1HM aay l lt Page 5 11 36998 281 B LON L 3A09 38999 781 9 1 3 ng ags9g zel 1 v COME L O0 ong er Soave 8588 68 v99 c8l v aay xyi G maj 6 one JOZC NVd3S Cardfolder III Service Manual Issue 1 Nov 2010 Scl LSl 3 Vvag 31VIdGd 104 0334 S3AOO 3015 133 3 3 03 dOl Lly 8 HOLIMS Liy 68 HOLIMS 8664 08 YOSNAS AVMV 3 55 8942 0581 YOSNAS 3 SLLASSV9D S3O9IA3d OLOHd 075 ma Q wa 064 081 QUvOS 3OSN3S 39 ONO Ir xy SIOSINO AJQZdl EI ma x 9 aaa S99 cBl JOS HOS jS LIX3 jLl3SSVO jS 3 ALLASSVO 100 140 CARDFOLDER II
14. 6 Reassembly is a reversal of removal ce There is no timing setting for fold plate 1 when the machine is next oper ated the fold plate will automatically align itself Page 3 10 Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL Fold 2 Rollers 1 These are located in front of the cassette Remove both side covers from the feeder section 3 4 and open the perspex top cover 2 On the drive side the pulley on the end of the upper roller shaft must be removed This is partially covered by the motor plate so this must first be moved it does not need to be completely removed Fig 8 shows the motor plate and the pulley to be removed 3 Slacken the belt tensioner on the horizon tal run of the drive belt 4 Remove the cassette pulley and belt and take out all screws on the motor plate 5 Move the plate sufficiently to remove the idler below the pulley and then remove the pulley and drive pin behind Note if you drop the idler behind the motor plate it can be removed from below by lifting up the front of the machine 6 The fold rollers can now be removed from the chassis after taking off the gears on the operator side 7 Reassembly is a reverse of removal noting the following points e Ensure the wavy washer is in place on the cassette shaft flanged bearing e Check that the sensor flag on the cassette pulley is properly aligned as described in Fig 5 e Tension the drive belt s
15. E a 9 e x m z N3 n H MOL 9 ven Ld MISd 7 i Li L vm e n LAM a N Fg Lv BET jnio 0 SOA A l ca Ly 19 29 SOA Cardfolder III Service Manual Issue 1 Nov 2010 Page 5 6 100 140 CARDFOLDER III SERVICE MANUAL J U 1 6 Busy 2 Z 5 9 2 3 4 2 Error 4 NS E O O CC 5 2 i 5 ee O 6 X I 6 RI R2 t ape 7 1KO 1KO aly z V a i PERDE O 5 O 2 O LD1 D2 7 Green Z Red ELO LO e Busy EXE Connect a 4 2mm PIH fixing hole PFE INTERNATIONAL LTD 280 789 ENGLAND to the mounting holes of CARDFOLDER INTERFAC C O C t O S J SEPTEMBER 2005 PCB NO 127 261 5 4 Cardfolder Interface PCB Circuit Diagram 180 789 ee VEO J R1 10R RX 2 J3 1 4 5 Ju R2 105 4 Tx 2 e Pis y 100R Z D PFE INTERNATIONAL LTD 180 790 INA148 ae CAKDFOLDER LONG SU RANGE SENSOR SEPTEMBER 2005 PCB NO 127 262 5 5 Cardfolder
16. lt lt lt lt lt lt See fixing kit A0 0602 A 91107055 for this assembly Note Fixings are not available indi vidually 4 1 Cardfolder Main Assy A5 0182 A Cardfolder III Service Manual Issue 2 Jun 2011 Page 4 3 100 140 CARDFOLDER III SERVICE MANUAL SCREWS E2830A ITEM 68 ARE FITTED IN ALL LOCATIONS MARKED BRIDGE CLAMPS G4092A ITEM 49 WITH M4 x 12 TORX HD d S ANNO CESS CEES SECC SSS SSCS 1 Ode ONE OM OU N US SESS NOTE 62 88888 PA d 47 4 2 Chassis Assembly A2 1406 A Operator side Page 4 4 Issue 5 Sep 2013 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL Item Part No WON AU N 131 823 169 112 169 115 169 140 169 144 169 160 179 110 181 018 181 069 181 569 182 444 B1 0967 A B2 1536 A B2 1537 A B2 1541 A B2 1543 A B2 1544 A B2 1564 A 9105932V 9100456R 9100459U 9100466B 9110677N 9110678P 9108383Y 9100706H 9105274K 9100831G 9101014X A2A A0007948 B7708A C2 1134 A G4 0149 A C3 0717 A C5 1142 A C5 1144 A C5 1145 A C7 0445 A C8078A DOO22A E0236A E0367A E0376A E0384A E4033A E1061A E1078A E1080A E5O71A E5074A E5098A F1 0452 A F1 0454 P F1196A F1243A F1251A F1428A F1434A F5011A F5054A 01670 G4092A P2065A P2247A 180 769
17. 13 D1040A 9103641 T BEARING 8mm 12SQ 8 Y 14 E0367A 9103789N WASHER WAVED 23mm ID 2 Y 15 E1061A 9103826B BEARING BALL 8x16x5mm 2 Y 16 E1078A 9103835L BEARING FL 8x22x7mm 2 Y i7 E2509A SCREW M4 x 8 SKT CAP HD 5 N 18 E2527A SCREW M5 x 16 SKT CSK HD 4 N 19 E2534A SCREW M5 x 25 SKT CSK HD 4 N 20 E2651A SCREW M3 x 6 SL POZI PAN HD 3 N 21 E2751A SCREW M5 x 8 SKT CAP HD 4 N 22 E4048A M4 WASHER FORM C 5 N 23 E5054A amm E CLIP 2 N 24 E5071A 9104133W PIN DOWEL 3 DIA x 14 m6 3 Y 25 E5073A 9 5mm E CLIP 1 N 26 F0 0058 A 9110701N INDEXING PULLEY 1 Y 27 1 0449 9110698K PULLEY 60Tx8mm HTD3 1 Y 28 F4266A 9106848Z GEAR FEED 15T 1M x 8mm 2 Y 29 G1136A 9104695G SPRING OMR SHAFT 4 Y 30 G6002A 9104868M WASHER 1 Y 31 181 128 9100807G CLUTCH W D 179 155 2WXH 1 Y Fixings Fixings marked are not available separately order Fixing Kit A0 0607 A 9110710X 4 8 Cassette A2 1410 A 9110669E Page 4 18 Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL 151 68 dJAOO MOVH 430104 ve ve Ol VA ddOvaoS 09 Was ed G H 10S N3S gue oe Vid NSM XL XM VN WOO VZ SZ3 L dH dvo 9 X v MINOS e pop LeZ ZBL NO88lM Z LIM3SNI AV WOOT Fe o d god FINGOW PAY NO p 5 OL 5 93 uH y P d ra i aa GL X W 5 G08 081 j 3g023v8 SSW ddd vZ1SZ3 ND god AINGON VAY NO er OL SLOJNNOO TH 9
18. 3 8 16 Configure system Before the machine is able to operate it must first be configured to reflect the actual hardware setup For example if the last sta tion is a 3 bin 3 plate folder this must be configured to reflect this Use the drop down lists to select the appro priate modules as shown below CONFIGURATION gt Module 1 StdFeed P Module 2 FeedTower P Module 3 CardFolder3 t Module 4 gt Continue If modules are changed or added at later date the machine must be configured again to reflect the hardware fitted or it will not be recognised After selecting the mod ule select Continue to move to the setup screen for the Insert Head as shown oppo site Insert Head Insert Head 60 Hz supply __ b Second wetter fitted gt Continue Select 60Hz supply only if the machine is 110v Select Second wetter fitted if the machine uses a high capacity wetter with a second wetter pump and drum of fluid in the stand When finished select Continue to move to the next module as shown below Issue 1 Nov 2010 Page 3 19 100 140 CARDFOLDER III SERVICE MANUAL Feeder Standard Dual amp OMR Bar code Module 1 0 5 OMR readers gt Barcode readers b Continue If the unit is an OMR Barcode feeder select the number of OMR and Barcode readers A maximum of either 4 x OMR or 1 x Barcode readers can be fitt
19. Note that the Cardfolder can also attach to another feed unit ie a feeder or folder 1 2 1 Connecting the Stands 1 Unpack the Cardfolder stand and assemble it using the supplied instructions Move the stand in line with the inserter stand or the stand for other feed unit attached to the inserter E P Connect the two stands together from the p ui 1 inside using the supplied fasteners in 4 cor ners see Fig 1 x N 3 Place the Cardfolder on the stand 1 2 2 Attachment of Cardfolder 1 Remove both side covers from the Cardfolder section 3 4 1 2 Connect the Cardfolder to the inserter or other feed unit using 2 x M5 screws each side supplied The spigots will locate the two units in line see Fig 2 3 Replace both side covers Page 1 4 Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL 1 2 3 Electrical Connections The Cardfolder is connected to the inserter or feed unit in front with a comms lead and a mains power cord The cables exit from the front corner through the end of the drive side skirt It is not neces sary to remove the skirt when connection but the drive side cover will need to be removed section 3 4 DIP Switch ON Position 1 Check that the DIP switches on the Cardfolder or feed module are set according to Fig 3 shown 2 Note that module 1 is the first feed unit The inserter head is hard wired at switch position 4 with DIP switch removed Locati
20. WASHER WAVED 23mm ID BEARING 8 x 16 x 5mm BEARING FL 8 x 22 x 7mm ROLL PIN 1 8 x 7 8 PIN DOWEL 3 x 14mm m6 PIN DOWEL 3 x 8mm m6 PIN DOWEL 3 x 18mm m6 PULLEY 20T x 8mm XL PULLEY 32T x 8mm XL PULLEY 40T XL GEAR 20T x 8mm 2 0M CLUTCH PIN EC30 SPRING PRESSURE WHEEL SPRING OMR SHAFT CASSETTE FEED GUIDE PRESSURE PAD COLLAR PRESSURE PAD BRACKET WASHER BRIDGE CLAMP III SERVICE MANUAL Qty Spares 1 A R A R lt lt 2 lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt 2 lt lt 2Z2222 lt lt lt lt lt lt lt NNBRONNANNNETNNAWADMDRDAANNANBPHBHBHBHHH HE SCREW M4 x 6 SKT SET 8 SCREW M4 x 8 TORX PAN HD 22 SCREW M4 x 12 TORX PAN HD TT 2 WASHER WAVED W61370 SPEC 2 9 5mm CLIP 14 See fixing kit A0 0603 A 9110706T for this assembly Note Fixings are not available indi vidually Page 4 10 Issue 3 Apr 2013 Output 4 4 Chassis Assembly A2 1406 A Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL T HD icum B M4 x 12 TORX LOCATIONS MARK z IN ALI 24 EWS E28350A ARE BRIDGE CLAMPS G4092A LB WIT oL 4 5 Infeed A2 1407 A Cardfolder III Service Manual Issue 1 Nov 2010 Page 4 11 NOIE Item Part No 100 140 CARDFOLDER III SERVICE MANUAL Description Qty Spares 1 169 140 9100466B CLIP RESTRAINT SM
21. and your new definition is now saved All OMR definitions created in Engineer mode will be available to the operator for selection when creating jobs that use OMR stationery When all settings for all units have been made select Continue you will be prompted to save your changes The machine is now configured and ready for use Page 3 24 Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL 3 9 Recommended Spare Parts List The following list shows spares that are recommended to be held in stock by Opcos and Ser vice Agents Quantities shown are per machine A full set of spares can be obtained by ordering Part Number 9110525E A0 0594 A SAP No 9100130B 9100302F 9108382X 9108383Y 9100510X 9100744R 9100751Y 9100753A 9105270F 9105271G 9110527G 9101013W 9101014X 9101015Y 9101087Y 9110518X 9105489 9110519Y 9110520 9103603U 9103613E 9103641 9105793A 9103789N 9103826B 9103835L 9104072H 9104089A 9104107U 9104121 9104124M 9104133W 9104135Y 9104142F 9104147L 9110006P 9109978K 9110521A 9104390P 9106545 9104430F 9104439Q 9104440R 9110522B 9110523C 9104471Y 9104505 9105216 91046110 91046445 Cardfolder III Service Manual NTL No 117 240 131 824 179 109 179 110 179 155 180 759 180 769 180 776 180 790 180 794 181 1670 182 443 182 444 182 445 182 693 184 2351 C6385A C7 0445 A C8 0213 A D0022A D0044A D1040A E0291A E0367A E1
22. LONG RANGE SENSOR 1 13 180 794 PCB ASSY PHOTOLOGIC DISK 1 14 180 8436 PCB ASSY CARDFOLDER I F 1 Lenze Clutches amp Motors 15 181 128 CASSETTE BRAKE LENZE 1 16 181 069 MAIN DRIVE MOTOR 230v 1 or 16a 181 569 MAIN DRIVE MOTOR 115v 1 17 181 1670 CASSETTE STEPPER MOTOR 2 18 181 1670 FOLDPLATE 1 STEPPER MOTOR Sensors 19 180 776 CASSETTE AWAY SENSOR 1 20 180 776 CASSETTE HOME SENSOR 1 21 180 776 FOLDPLATE 1 DOWN START POS SENSOR 1 22 180 776 FOLDPLATE 1 UP START POS SENSOR 1 23 180 776 FOLDPLATE 1 HOME POS SENSOR 1 24 182 343 FOLDPLATE 1 SENSOR TX 1 25 182 344 FOLDPLATE 1 SENSOR RX 1 26 182 440 DESKEW SENSOR TX 1 27 182 443 CASSETTE ENTRY SENSOR TX 2 28 182 444 CASSETTE ENTRY SENSOR RX 2 39 182 445 DESKEW SENSOR RX 1 30 117 240 CASSETTE EXIT SENSOR TX matched with item 31 1 31 117 240 CASSETTE EXIT SENSOR RX matched with item 30 1 32 182 693 INFEED SENSOR REFL 1 For all optical pair sensors TX is upper RX is lower t Sensor PCB for these looms is a discrete item and must be ordered separately See diagram section 5 6 for part numbers Switches PSU Fuse amp Reader PCB wiring 36 135 105UL 37 180 805 FUSE 20mm 5A A SURGE not shown PCB MS3 BARCODE IF Used only when reader is fitted 33 182 417 WIRED REED SWITCH TOP COVER 2 34 182 417 WIRED REED SWITCH SIDE COVER 2 35 184 2351 AM4 CARD FOLDER PSU ASSY not shown 1 1 1 For part numbers of PCB looms and ribbon cables see wiring diagram section
23. Long Range Sensor PCB Circuit Diagram 180 790 Cardfolder III Service Manual Issue 1 Nov 2010 Page 5 7 100 140 CARDFOLDER III SERVICE MANUAL L JO L ye us OLOZ 50 ysnbny Aopsunu 81g L PrOLEZ ZZL ev JequinN iueuinoo aZIS 920J491U 4eplOofp4og aL YLOH Z lt A 8 6 jen Cly O DOA yLOHr A 4 9 S oen anyo LLL 4nool 1 OAL 77 QNO LO ZLY O DOA OON 7 QNO N3 dd c gyno QNO g aNd 2440 XMLZNVO c AIgS6dJ c Nilda G VHINO XYZNVO 7 10S Edd _ g LYAO 29 99 1 29 JOS 1OSX ozr y01 r 8 vas vOsx Lar Q VCLOW 6 OldO OL 40 6 og Q 7 7 9 6 Z 9dO 840 Z 6 ZdO 9 gz S n S 86 1 1 LZ 9 rC IAPS e Vra 4 z L L Q 8d3S Sd LMJ3AOO SZ 6 AXGSdl 6 Sa e 5 b ddas Sd ud A 7 Le L 77 9 e cal b Vd3S 9 ez 7 gy ez tle bel MSIGUNO Zdl v zz p GM a ZZ 518 299 LP 0 Li VLOHVZ VLOH
24. WASHER WAVED 8 89ID12 50DO 18THK 3 Y 19 E5071A 9104133W PIN DOWEL 3 DIA x 14 m6 3 Y 20 E5073A 9 5mm E CLIP 8 N 21 E5086A 9104142F PIN DOWEL 3 DIA x 16 m6 SS 1 Y 22 E5098A 9104147L PIN DOWEL 3 DIA x 18 m6 SS 3 Y 23 1 0449 9110698K PULLEY 60Tx8mm HTD3 1 Y 24 F1 0450 A 9110684V PULLEY 32T XL 1 Y 25 F4134A 9104390P GEAR FOLD 20Tx8mm 2 0M 3 Y 26 F4 0308 A 9110521A GEAR 20Tx22mm 2 0M 1 Y 27 G1060A 9104644D SPRING RETURN 2 Y 28 G4092A 9104827U BRIDGE CLAMP 4 Y 29 E0291A 9105793A FOOT PUSH IN HEYCO 0862100 4 Y Fixings Fixings marked are not available separately order Fixing Kit A0 0606 A 9110709W 4 7 Fold Wing A2 1409 A 9110668D Page 4 16 Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL Sx f oN m NOIE ORIENTATION lt 4 8 Cassette A2 1410 A 9110669E Cardfolder III Service Manual Issue 2 Jun 2011 Page 4 17 Item Part No 100 140 CARDFOLDER III SERVICE MANUAL Description Qty Spares 1 B2 1520 A CASSETTE INDEXING PLATE 2 N 2 B2 1521 E CASSETTE PLATE 2 N 3 B3 1258 A 9110699L CASSETTE INDEXING FLAG 1 Y 4 C2 1132 A CLUTCH SHAFT LOCATOR 2 N 5 C2 1133 A 9110700M BEARING SPACER 1 Y 6 C4 0551 A SHAFT CASSETTE DRIVE 1 N 7 C4 0552 A SHAFT CASSETTE INDEXING 1 N 8 C6397A 9108695Y CASSETTE SHOE 4 Y 9 C9638A FEED GEAR SHAFT 2 N 10 C9639A INDEXING TIE BAR 4 N 11 C9699A FEED SHAFT 2 N 12 D0022A 9103603U ROLLER TRANSPORT 25 x 8 1 Y
25. axis The fold rollers are of uncoated cellular rubber construction Immediately before it are 2 pairs of feed rollers belt driven together and controlled by a wrap spring clutch on the front pair The rear pair acts as deskew rollers with the deskew sensor located just before them FP1 sensor is located between the pairs which monitors the paper as it enters and exits fold 1 The module operates in 3 possible positions up down or centre depending upon fold type It is rotated to the appropriate position by a stepper motor rotating either clock wise or anticlockwise the stop point is monitored by one of 3 flag sensor triggered by the same flag at one end of the fold plate Figs 3 4 amp 5 below show the positions Cassette entry off 1 Up sensor Step 1 Flag sensor Start position q for Up fold a Fig 3 O Cassette entry sensor O 1 Z 5 O OPA j e h 255 FP1 Down sensor Paper path off FP1 Up sensor e e Step 1 Flag sensor Start position q for Down fold on On er UOS Fig 4 Page 2 4 Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL Cassette entry sensor aper path
26. i FP1 Down sensor e FP1 Up sensor ND Step 1 Flag sensor Position for no fold Ee L Fig 5 The outfeed from the fold 1 sub module is via the fold rollers described above driven direct from the main drive 2 2 4 Fold 1 Operation Depending on the fold type selected the process would have started with FP1 in one of the 3 positions eUp Standard Z fold V fold with address on reverse side e Down C fold Standard V fold Bottom address Z fold e Centre No fold Assuming all is clear up stream at the end of the deskew timer the clutch on the feed rollers will energise The document will advance for a distance according to the select ed fold length then apply brake and disengage clutch The distance is timed from the leading edge passing FP1 sensor FP1 will now move either up or down to the centre position After a short delay the feed rollers will restart moving the partially folded document into the nip of the fold rollers which completes the fold and transfers the document towards the Fold 2 sub module If no fold had been selected the fold plate assy would start in the centre position with the document being passed straight through this is an unlikely situation 2 2 5 Fold 2 Description Fold 2 sub module comprises a rotary folding cassette in which are mounted 2 pairs of feed roller shafts each with 4 rollers One shaft of each pair is spring loaded against the other driven shaft The driv
27. in front Connect the power lead from the mains to the insert head At this point installation for the machine is complete and the three steps below should be carried out 6 Enter Engineer mode and check the machine configuration see section 3 8 16 Con figure System If not configured do so now Switch the machine on and run in burn in mode for a while to check all is OK If required run installation checks and setup described in section 3 7 Not all checks will necessarily apply but it is important they are performed where necessary particularly if operating problems occur on the customer s job 8 Switch off and refit all covers Instruct operators how to run the machine change or set up jobs etc aS appropriate Particularly instruct operators how to clean sensors 1 2 4 Attachment of Card Processor The Cardfolder can interface with a variety of card processing machines and a number of different fixing kits are available For full details and part numbers see the 100 Cardfolder Product Guide or contact the IPSS department Page 1 6 Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL Section 2 Description of Operation Sect 2 1 2 2 2 2 1 22 2 2 2 3 2 2 4 2 25 2 2 6 Cardfolder III Service Manual General Cardfolder Sub Modules Infeed Description Infeed Operation Fold 1 Description Fold 1 Operation Fold 2 Description Fold 2 Operation Page
28. m6 SS 6 Y 37 E5126A 9110006P PIN GROOVED 3DIAx8 SS 4 Y 38 F1243A 9104274T PULLEY 18XL x 8mm 4 Y 39 F4 0293 A 9109978K GEAR 40T 1M IDLER 1 Y 40 F5002A 9104430F BELT 140XL 037 2 Y 41 01670 9105216 CLUTCH PIN EC30 2 Y 42 G4092A 9104827U BRIDGE CLAMP 4 Y 43 179 110 9108383Y CLUTCH EC30LL CCW 8mm24V 2 Y 44 180 760 9100745S PCB SPLIT 3SEN 4SOL H D 1 Y 45 E2 0836 A SCREW M4 x 6 TORX PAN HD SS 2 N Fixings Fixings marked are not available separately order Fixing Kit A0 0604 A 9110707U 4 5 Infeed A2 1407 A Page 4 12 Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL s YW 4 6 Fold Wing Infeed A2 1408 A 9110667C Cardfolder III Service Manual Issue 2 Jun 2011 Page 4 13 Item Part No 1 B1 0966 A 2 B2 1533 A 3 B2 1534 A 4 C5 1134 A 5 C5 1138 A 6 C5 1140 A 7 C7 0445 A 8 D0022A 9 DO 0073 A 10 D1040A 11 E0376A 12 E2509A 13 E2830A 14 E3505A 15 E4011A 16 E4048A 17 E5073A 18 G1136A 19 G1184A 20 G1185A 21 G4092A 22 E0291A 23 182 443 Fixings 9103603N 9110696H 9103641 9103789N 9104695G 9105602B 9105590P 9104827U 9105793A 9101013W 100 140 CARDFOLDER III SERVICE MANUAL Description FOLD WING INFEED UPPER FOLD BAFFLE UPPER LATCH SHAFT INFEED SUPPORT SHAFT FOLD BLADE UPPER SHAFT LATCH PIVOT FOLD BLADE ROLLER TRANSPORT 25x8 VINYL CAP 53x13x1 5 BLUE T BEARING 8mm 12SQ BUSHING SHORTY 19 I D SCREW M4 x 8 SKT CAP HD SCREW M4 x 12
29. of clothing becomes caught in one of Page 1 2 Issue 1 Nov 2010 the moving parts you may be pulled into the machine very quickly This force can be surprisingly powerful you may not be able to resist it Take care with neckties sashes long sleeves or any other loose clothing Dangling jewelry can also present a hazard Remove any of these items of loosely fitting clothing or tie the loose sections out of the way so they can t be caught by the machine Long hair can also be dangerous when work ing near this type of machine If you have long hair tie it back or tuck it under a hat Be especially careful around the folding roll ers in the machine Caution Keep the machine clean Wipe off the outside of the cabinet from time to time to keep the paper dust from collecting If you notice that paper dust is collecting inside the machine open the cov ers and vacuum it out or blow it out with an airduster Caution Keep the work area around the machine clean Don t allow paper trim and waste to pile up If the work area in cludes a lot of loose paper scraps an opera tor may slip and fall BEFORE DISASSEMBLING THE MAIN POWER CABLE MUST REMAIN UNPLUGGED UNTIL END OF ASSEMBLY DO NOT TOUCH INSIDE POWER SUPPLY UNIT TO PREVENT ELECTRICAL DISCHARGE DUE TO CHARGED CAPACITOR ALTHOUGH MANUFACTURER TAKES CARE TO REDUCE RIDGE DANGER PLEASE HANDLE STEEL SHEETS CAREFULLY TO AVOID ALL RISKS OF CUTTING IMPORTANT
30. safety grounding fea ture Be sure the plug is always connected to a properly wired three prong outlet Do not use a two prong adapter without grounding the machine properly Never remove the third prong from the plug The safety grounding feature provides extra pro tection in the event of an electrical problem The apparatus must be earthed As the colors of the wires may not corre spond with the colored markings identify ing the terminals in your plug proceed as follows The wire which is colored GREEN must be connected to the terminal in the plug which is marked by the letter E or by the safety earth symbol or colored GREEN The wire which is colored WHITE must be connected to the terminal which is marked with the letter N The wire which is colored BLACK must be connected to the terminal which is marked with the letter L Warning The mains input supply is fused on both live and neutral sides Ser vice personnel should be aware that a mains voltage can exist even if no lighted neon shows Warning Most of the moving parts are protected by covers Don t operate the ma chine unless all of the covers are in place Opening covers include safety interlock switches If a cover is opened the switch will stop the machine from running Don t try to bypass the interlocks and don t use the machine if the interlocks are not work ing Warning Don t wear any loose clothing when you are working near the machine If a bit
31. screws on the three tabs indicated below Drop the skirt slightly to free the lugs on the lower edge When replacing ensure these tabs are properly located in the chassis Page 3 6 Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL 3 4 3 Operator side cover The operator side cover can be opened by opening the top cover and pulling down the side cover using the cutout in the chassis for finger access Normally it will not be necessary to remove the cover completely but if this is required or the operator side wiring skirt has to be removed take out the 4 x M4 screws on the two tabs indicated below Drop the skirt Slightly to free the lugs on the lower edge When replacing ensure these tabs are properly located in the chassis Cardfolder III Service Manual Issue 1 Nov 2010 Page 3 100 140 CARDFOLDER III SERVICE MANUAL 3 5 Removal of Cassette The cassette performs the second fold and contains 2 pairs of feed rollers which are actu ated to drive the folded document out at the appropriate time The rollers are driven via a clutch from the constantly rotating main drive while the cassette is locked in place by a Lenze brake The cassette is rotated by stepper motor The cassette can be easily removed for maintenance should the rollers need replacement the procedure is described below 1 Remove both side covers from the feeder section 3 4 and open the perspex top cover Disconnect the Len
32. when the paper enters N b the cassette has 2 logical positions referred to as Up and Down by way of definition the cassette is in the Up position when the gear driven feed rollers are topside sprung ones underside If the selected fold is either V or None then the cassette only serves to transfer the document through itself to the output fold rollers and on to the Maximailer When folding the stepper motor rotates the cassette either clockwise or anticlockwise depending upon fold type e Anticlockwise Standard Z fold amp C fold e Clockwise Bottom address Z fold The cassette will be in the up position at the start of the process ie paper can feed into it as shown in Fig 6 below Its position either up or down will be indicated by a single flag interrupting the Cassette away sensor for down position or Cassette home sensor for up position Cassette exit sensor Cassette entry Cassette away sensor sensor _ Cassette home Cassette exit sensor Lo Start position for cassette Fig 6 cont Page 2 6 Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL FP1 will outfeed the document towards the cassette The feed rollers will start ready to receive it Fold 1 of t
33. will determine whether foldplate moves up or down for first fold This setting calibrates the depth of paper into the foldplate FP2 Clockwise Counter CW Cal Fold type will determine whether cas sette rotates CW or CCW for second fold This setting calibrates the depth of paper into the cassette when the roller springs are uppermost see also Delta setting below FP2 Clockwise Counter CW Delta Because the cassette turns 180 to receive the next form the feed rollers rotate the other way and require a sec ond calibration Delta setting calibrates the depth of paper into the cassette when the roller springs are downmost Conclusion of Settings section 3 8 7 Power This provides a read only display of voltages and currents of various supply sources The voltage current readings are displayed to two decimal places 3 8 8 Drivers Allows various components to be switched on or off to test them and provide a read out of current rating Components shown will depend upon type of unit selected and will include some or all of clutches brakes solenoids and indicator LEDs Drive motor is also included for each module as this must be switched on to test some other compo nents 3 8 9 Motors This allows you to switch motors on or off to test them and provide a readout of cur rent rating Motors shown will depend upon type of unit selected and will include some or all of accumulator stepper insert fingers collate poc
34. 00 0133 5009 8 Feature Set 3 8 19 OMR Definition Creating an OMR definition allows the opera tor to select it for use in a job setup Up to 9 definitions can be created depending upon the option chosen at machine purchase The template for the definitions will have default name usually OMR 1 OMR 2 etc which can be renamed after defining Cardfolder III Service Manual Scroll down to OMR definition and select one of the available templates either an unused one for creating a new defintion or an existing one for editing ENGINEER P Env Only Mode D Set Default Supervisor PIN gt View throughput D Sensor Cal Super gt CONFIGURE SYSTEM D Licence Set up OMR definition f1 Flex1 J KBCR definition a Adv J You can now make required selections from the template see descriptions opposite EDT OMR1 P Cede Type 1 track 5 b Number of marks PD Gate mark L g Pitch gt Parity DReverse seq order Invisible gate mark P Form seq start count w Note A full description each mark can be found in the OMR Specifications document for 100 140 Series Code type Options are 1 track 2 track Number of marks Up to 20 Gate Mark Options are Top Bottom Left Right Refers to the position of the mark as printed relative to the address printing ie Left and Right refer to ho
35. 061A E1078A E4033A E5005A E5027A E5050A E5054A E5071A E5074A E5086A E5098A E5126A F4 0293 A F4 0308 A F4134A F4266A F5002A F5011A F5012A F5 0173 A F5050A F5054A F5125A G0167P G1008C G1060A Description OPTO PAIR LONG RANGE SWITCH MAGNET SMALL CLUTCH EC30LL CW 8mm 24V CLUTCH EC30LL CCW 8mm24V CLUTCH LENZE PSI O4 24V PCB SPLIT 5SEN 5SOL H D PCB ASSY AM4 STEPPER PCB WIDEBODY DISK SENSOR PCB LONG RANGE SENSOR PCB ASSY PHOTOLOGIC DISK MTR W D 179 1000 STEPPER LOOM EMITTER 300 XH LOOM RECEIVER W A 300 XH LOOM RECEIVER N A 300 XH OPB715 WIRED SENSOR 2x3W CARDFOLDER3 PSU ASSY 26V PRESSURE PAD FOLD BLADE FOLD ROLLER ROLLER TRANSPORT 25x8 ROLLER TRANSPORT 40x15 T BEARING 8mm 12SQ FOOT PUSH IN WASHER WAVED 23mm ID BEARING BALL 8x16x5mm BEARING FL 8x22x7mm WASHER WAVED W61370 SPEC ROLL PIN 1 8x7 8 ROLL PIN 1 8x1 CIRCLIP N1800 0037 3 8 CIRCLIP E 8mm PIN DOWEL 3 DIA x 14 m6 PIN DOWEL 3 DIA x 8 m6 PIN DOWEL 3 DIA x 16 m6 PIN DOWEL 3 DIA x 18 m6 PIN GROOVED 3DIAx8 ST ST GEAR 40T 1M IDLER GEAR 20Tx22mm 2 0M GEAR FOLD 20Tx8mm 2 0M GEAR FEED 15T 1M x 8mm BELT 140XL 037 BELT 120XL 037 BELT 190XL 037 BELT 330DXL 037 BELT 149T HTD 447 3M 09 BELT 188T HTD 564 3M 09 BELT 510DXL 037 CLUTCH PIN EC30 SPRING PRESSURE WHEEL SPRING RETURN Issue 1 Nov 2010 Qty NJ 4 N N m m N 4 N 4 I N O NB N E NN AN CO NJ E N F HI Hd
36. 100 140 CARDFOLDER III SERVICE MANUAL TABLE OF CONTENTS 1 Unpacking and Installation 1 1 1 1 Safety 1 2 LA 2 een re 1 4 1 2 1 Connecting the Stands 1 4 1 2 2 Attachment of Cardfolder 1 4 la Repent cent uu 1 5 1 2 4 Attachment of Card Processor 1 6 2 Description OF Operation 2 1 a a i eer eee Renner nnn ern ne ee ee ee 2 2 2 2 Cardfolder sub 2 3 2 2 1 Infeed Description iiis ee ec c cc c 2 3 2 2 2 Infeed OU PX oct 2 3 Zo VOW 1 VEXPEUPA 2 4 dug FOG L 2 5 2 2 9 BON 2 cans 2 5 560 Fod 2 ODEON cese dg sae tpa v OR RR 2 7 3 Service and Operating Adjustments 3 1 3 1 Health Safety and Environment 3 2 3 2 Conventions used in this Manudi EYES 3 4 3 3 Information for 9 665 r r 3 5 3 4 Removal NEREA AERA
37. 2 2 2 3 2 3 2 3 2 4 2 5 2 5 2 7 Issue 1 Nov 2010 Page 2 1 100 140 CARDFOLDER III SERVICE MANUAL 2 Description of operation 2 1 General The sole function of the Cardfolder CF is to receive a document with card cards at tached from a card affixing machine prepare this for inserting and pass this onto the inserter Fig 1 shows a side view of the paper path Fig 1 Typically the CF will fold the document into Z C or V fold although it is theoretically possible to pass a document through the unit unfolded which must be envelope sized It is also possible to perform a Double V fold The CF can process documents with up to 4 cards attached however these cannot be placed in the upper panel The specifications in the Operator Manual define the allow able card positions relative to the folds The CF must be the end module of the folder inserter system which can then support up to a further 3 modules from the standard range The flex folder is not a possible option The inserter system wh
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40. 8 6 umd k T yid van den mm 0L Ll TlOHvL dals gen OSL Ly 1 29 JOJDOULOD AT L Tm 8010Ht 4 e eL Z N IDA 1s9 cle 5 y aen Ol g n LOHvZ ZS S TiOHvZ ANA y 9 36 d3MA dais 9 S Old BOLOHPL E z d3lS was a oen L ze lvSd 95 2 OLM gcn JON O L gn Lt LON 29 GN2NW LL 73 n i i VL AMLILOHOS EE VL AMLLOHOS TE e ed ai zd 1 0s0 c081sd 24 L671 3d00S 92 MET N3n ONAS xal LM Ly gr L L66dO0 v 9 gp 35 35 3 Fe HH v p e sp 135 35 550 nk i Z gj pu OM vas aa m gt 0797 cH LONI NJ Fo vin ep po _ Peg HOLZ 14 9 q 154 e eo or 6 OZ 9n jSN3S J H MY Gus ANG O L g 6l cy OMIL 198 L 1 jnio 0 MOZZ 94 i EE HE 9 TEE EI mo L8 d3lS z 1 54 069 z5 29 l 99 v 99 9 on e aaa LLNO O L M3dd3lS MOL ah oe l 22 99 7 LL IA id N 7 umoig auum 8 z S IN e MzSd Bupio 6 BupiO eyuM 3 5 N j S e er BAUR ee n mo eA exuM f pee 0797 lt eyuM aene 5 9 gp 35 35 2 dinero 6 juzz jnio 0 Zn 7 a iji a BOLOHY dun Br LYNE 619 go 8 idus jni o uorz L i LINO 1 e
41. 9105533E 9119106T 9119108V 9119109w 9110519Y 9105500V 9103603U 9103764M 9103789N 9105808R 9103764M 9104072H 9103826B 9103835L 9103836M 9104133W 9104135Y 9104147L 9110680R 9110681S 9104253W 9104274T 9106616H 9106964V 9109283L 9104439Q 9104471Y 91052162 9104827U 9106018K 91050247 4 2 Chassis Assembly A2 1406 A Cardfolder III Service Manual Description SWITCH REED SMALL PCLIP 1 4 RIVET 5mm 2 5 3 5 GRIP CLIP RESTRAINT SMALL CLIP 34W RIBBON CABLE CLAMP 34W RIBBON FCCS 4 CLUTCH EC30LL CCW 8mm24V MOTOR ASSY STEPPER 1206 MTR WD 179 072 4WJST CW 230V MTR W D 179 073 4WJST CW 115V LOOM RECEIVER W A 300 XH FOLD WING INFEED LOWER FOLD BAFFLE LOWER CHASSIS SIDE PLATE OP CHASSIS BRIDGE BEARING BRACKET CLUTCH LOCATOR 1 LOWER PANEL INFEED ROLLER CLUTCH HOUSING SENSOR DISC 130 SLOT PIVOT HOUSING FOOT SPIGOT INFEED PIVOT SHAFT MAIN DRIVE SHAFT FOLD DRIVING SHAFT FOLD DRIVEN FOLD BLADE RUBBER FOOT ROLLER TRANSPORT 25x8 FAN 2 5 8 WASHER WAVED 23mm ID BUSHING SHORTY 19 I D SPACER M4 x 12 HEXAGON WASHER WAVED W6130 SPEC BEARING BALL 8x16x5mm BEARING FL 8x22x7mm BEARING BALL 3 8 MINIATURE PIN DOWEL 3 DIA x 14 m6 PIN DOWEL 3 DIA x 8 m6 SS PIN DOWEL 3 DIA x 18 m6 SS PULLEY 26Tx3 8 PULLEY 24Tx3 8 PULLEY HTD3 96 MOULDED PULLEY 18XL x 8mm PULLEY HTD 20Tx8mm 50Hz PULLEY 16HTD3x8mm 60Hz PULLEY 20XL CLUTCH BBRG BELT 120XL 037 BELT 188T HTD 564 3M 09 CLUTCH PIN EC30 BR
42. ALL 2 Y 2 182 443 9101013W LOOM EMITTER 300 XH 1 Y 3 182 444 9101014X LOOM RECEIVER W A 300 XH 1 Y 4 182 693 9101087Y OPB715 WIRED SENSOR 2x3W 1 Y 5 B1 0965 A INFEED BRIDGE 1 N 6 B2 1525 A INFEED SIDE PANEL DR 1 N 7 B2 1526 A INFEED SIDE PANEL OP 1 N 8 B2 1544 A CLUTCH LOCATOR 1 1 N 9 B2 1545 A CLUTCH LOCATOR 2 1 N 10 B2 1848 A INFEED SENSOR BRACKET 1 N 11 B2 2069 A INFEED BOGEY 1 N 12 B3 1259 A 91106908 INFEED SIDE GUIDE DR 1 Y 13 B3 1260 A 91106916 INFEED SIDE GUIDE OP 1 Y 14 B3 1503 A SENSOR BRACKET 1 N 15 C2 1024 A 9109565E CLUTCH PLATE STANDARD 1 Y 16 C2 1135 A 91106920 ROLLER INFEED 10 Y 17 C5 1134 A SHAFT INFEED SUPPORT 1 N 18 C5 1135 A 9110693E SHAFT INFEED DRIVEN 2 Y 19 C5 1136 A 9110694F SHAFT INFEED DRIVING 1 Y 20 C5 1137 A 9110695G SHAFT BOGEY 3 Y 21 D0044A 9103613E ROLLER TRANSPORT 40x15 2 Y 22 D1040A 9103641 T BEARING 8mm 12SQ 10 Y 23 E0330A 9105861W WING BOLT NYLON M5 x 15 MALE 4 Y 24 E0367A 9103789N WASHER WAVED 23mm ID 6 Y 25 E0376A 9105808R BUSHING SHORTY 19 I D 4 Y 26 E0384A 9103764M SPACER M4 x 12 HEX 2 Y 27 E1061A 9103826B BEARING BALL 8x16x5mm 1 Y 28 E1078A 9103835L BEARING FL 8x22x7mm 7 Y 29 E2830A SCREW M4 x 12 TORX PAN HD T T 4 N 30 E3505A NUT M4 NYLOC 2 N 31 E4011A WASHER M4 FORM A 2 N 32 E4033A 9104072H WASHER WAVED 8 89ID12 50DO 18THK 1 Y 33 E5071A 9104133W PIN DOWEL 3 DIA x 14 m6 4 Y 34 E5073A 9 5mm CLIP 14 N 35 E5074A 9104135Y PIN DOWEL 3 DIA x 8 m6 SS 3 Y 36 E5086A 9104142F PIN DOWEL 3 DIA x 16
43. Collate Pkt Guide 0 1mm n 3 b Set Fingers to 210mm b Fingers Cal 0 1mm This screen applies only to the insert head and is used to set the collate pocket side guides and the insert fingers to A4 size 210mm When these options are selected the motors for the settings will automatically adjust to the correct size They should then be measured and any difference should be corrected out using the adjustment boxes positive numbers increase the width Cardfolder III Service Manual Note that the measured distances should be 210mm exactly Appropriate clearances will then be automatically applied by the soft ware which will suit most job applications It it is required to alter the settings use the adjustment boxes as described above These settings will then remain until set otherwise Note also that the collate pocket side guides are adjustable for taper and are factory set to taper intowards the closer end The 210mm setting above applies to the narrow est point the widest point is set to approx 3 4mm wider either side Specific jobs may require a diferrent setting to adjust slacken the screw near the middle of the guide and twist the guide to suit To exit Calibrations press the x button 3 8 6 Settings This allows adjustment of various settings depending upon the module Head end adjustment of Collate Pocket Cal amp Fingers Cal These settings are in addition to any changes made in Cal
44. ER ROLLER TRANSPORT 40x15 FOOT PUSH IN WASHER WAVED 23mm ID BEARING BALL 8x16x5mm BEARING FL 8x22x7mm WASHER WAVED W61370 SPEC CIRCLIP N1800 0037 3 8 CIRCLIP E 8mm PIN DOWEL 3 DIA x 16 m6 PIN GROOVED 3DIAx8 ST ST GEAR 407 1M IDLER GEAR 20Tx22mm 2 0M GEAR FEED 15T 1M x 8mm BELT 140XL 037 BELT 190XL 037 BELT 330DXL 037 BELT 149T HTD 447 3M 09 BELT 510DXL 037 SPRING RETURN SPRING LATCH RH SPRING LATCH LH WASHER CASSETTE FEED GUIDE Issue 2 Aug 2012 Qty N i N mP rm rm N mP FU N N N O ENNA FEF N N R mp mE m N Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL Section 4 Exploded Views Sect Page 4 1 Cardfolder Main Assy A5 0182 A 4 2 4 2 Chassis Assembly A2 1406 A Operator Side 4 4 4 3 Chassis Assembly A2 1406 A Drive Side 4 7 4 4 Chassis Assembly A2 1406 A Output 4 9 4 5 Infeed A2 1407 A 4 11 4 6 Fold Wing Infeed A2 1408 A 4 13 4 7 Fold Wing A2 1409 A 4 15 4 8 Cassette A2 1410 A 4 17 4 9 Cardmailer BCR Kit A3331A 4 19 4 10 Cardfolder BCR Kit A3326A 4 20 Cardfolder III Service Manual Issue 1 Nov 2010 Page 4 1 100 140 CARDFOLDER III SERVICE MANUAL S ej 5 e J S ANN NN SPEAN 4 1 Cardfolder Main Assy A5 0182 A Page 4 2 Issue 2 Jun 2011 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL Item
45. I SERVICE MANUAL Page intentionally left blank Page 5 12 Issue 1 Jan 2011 Cardfolder III Service Manual
46. IDGE CLAMP LATCH SPIGOT SHORT MODULE LOCATION SPIGOT AM4 STEPPER PCB Operator side Issue 5 Apr 2013 Qty A R A R A R A R A R SNS lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt 2Z222 lt lt 2Z2222222 lt lt N F a QQ O ONA N OO N N PUR OO N E m m m N rm mp P Hp P N N PF mp mp Spares lt lt lt lt lt lt lt lt lt lt 2 lt lt lt lt lt lt lt Page 4 5 Item Part No Fixings 60 E2053A 61 E2505A 62 E2826A 63 E2 0840 A 64 E2534A 65 E2537A 66 E2606A 67 E2793A 68 E2830A 69 E2504A 70 E3505A 71 E3527A 72 E3557A 73 E4011A 74 E4012A 75 E4048A 76 E5050A 77 E5073A 100 140 CARDFOLDER III SERVICE MANUAL Description Qty Spares SCREW M3 x 8 SKT CAP HD SCREW M4 x 6 SKT SET SCREW M4 x 8 TORX PAN HD SCREW M5 x 10 TORX PAN HD SCREW M5 x 25 SKT CSK HD SCREW M4 x 10 SKT CSK HD SCREW M5 x 16 SKT CAP HD SCREW M3 X 25 SKT CAP HD SCREW M4 x 12 TORX PAN HD TT M5 NYLOC NUT M4 NYLOC NUT M8 NUT M3 NYLOC NUT M4 WASHER FORM A M5 WASHER FORM A M4 WASHER FORM C CIRCLIP N1800 0037 3 8 9 5mm E CLIP D a ee T roe See fixing kit A0 0603 A 9110706T for this assembly Note Fixings are not available indi vidually Spares Assemblies SA1 A2A A0007948 Page 4 6 ROLLER CLUTCH HOUSING A R 4 2 Chassis Assembly A2 1406 A Issue 3 Ap
47. MJHOS Lei Ze ASO ANOT 2 8 SSW WOO MEUSE GH dvO OL X VA MidOS 351598 H Jiv id 4q S VLLOYJ ISHSVM VW VLOGC4 Syd OL X vA Y S 52 IVOLLS dA JAIS vd F9 07 S3NNVOS 3UOOsVg c E 6 IVOLLS dA I YSOSC4 LON OQOTAN 27 NOILISOd INNON YANNVOS 3ALLVNS3 V 3 llS 1000 PN Md33429S un dH dvO vl x 5 9S Cel 7 GO avg Jll v600t3 YSIHSVM N VERSES GH Nvd LOIS 9 X GEN 2 3 IVWOSvO Veo LZ I4A00 dol VEvLoo YOSNAS 4 9 Cardmailer BCR Ki A3331A eleva sls 994969 dvd 330 17 4040011 Page 4 19 Issue 1 Dec 2012 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL O9 Os L A amp 8 15 VH
48. PE AV 138 YOLOW mo Cai Q3HOIIMS Q3HOIIMS A9Z C5 G PO TO OP S9C ren God jSfl4 VS TS LS 1 1 imm Nmt 0009 i ic ISNI digo AYE 3er VS NS8O AlddnAS 20 WOO 9L c8Ll WOOT ONIGIM 06746 8l LSAP OY OVLTOA 118 A18 LS LS I34 N39 3 L N 11H e 7 NYG C S gem 5 I34 N39 I3A NND 6 19 ma L Ol MO MOLOIN OV dvo jne Nag Lol 118 118 Nd L i Z G E L ASLL 693 9 690 181 14A NAD 11H Nad s Had AYE OO0LSMZ Nad IHA NM9 L3 SNIVIA QV3 L3 INI SNIV Page 5 9 Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER IIT SERVICE MANUAL Or 68429 S ECT weibeig BuilM 2eJi43 1uI opooJeg 9
49. Part No 1 131 824 2 A2 1406 A 3 A2 1407 A 4 A2 1408 A 5 A2 1409 A 6 A2 1410 A 7 B1 0968 T 9 B1 0969 T 9 B2 1546 A 10 B3 1262 T 11 B3 1263 T 12 B3 1271 A 13 B3 1272 A 14 B3 1273 A 15 B9113T 16 C4366A 17 F5001A 18 F5012A 19 F5050A 20 F5054A 21 F5125A 22 F5 0173 A 23 G4140A 24 G7 0189 A 25 R2854T 26 B2 2232 A Fixings 40 E2 0862 A 41 E2590A 42 E2826A 43 E2564A 44 E2 0840 A 45 E4011A 46 E3557A 47 E3505A 9100302F 9110665A 9110666B 9110667C 9110668D 9110669E 9110670F 9110671G 9110672H 9110673 9110674K 9106257 9104429E 9104440R 9110523C 9104471Y 9104505 9110522B 9110675L 9110676M Description SWITCH MAGNET SMALL CHASSIS INFEED FOLD WING INFEED FOLD WING CASSETTE SIDE COVER OP SIDE COVER DR COVER HANDLE WIRING SKIRT DR WIRING SKIRT OP MAGNET BRACKET HINGE STAY 1 HINGE STAY 2 CARD FOLDER BACK COVER HINGE PIN BELT 130XL 037 BELT 190XL 037 BELT 149T HTD 447 3M 09 BELT 188T HTD 564 3M 09 BELT 510DXL 037 BELT 330DXL 037 HINGE EXTRUSION DISPLAY PANEL INFEED PLATE WIRING GUARD SCREW M3 x 10 TORX PAN HD SCREW M3 x 12 SL CSK HD SCREW M4 x 8 TORX PAN HD SCREW M4 x 12 SKT CSK HD SCREW M5 x 10 TORX PAN HD M4 WASHER M3 NYLOC NUT M4 NYLOC NUT Qty Spares N N N NJ N E P EN gt lt lt 2 lt lt lt lt lt lt lt lt 2 2 2 lt lt 2 lt lt
50. R 1 Y 23 C3 0717 A INFEED PIVOT 1 N 24 C3 0718 A MOTOR PLATE SPACER 6 N 25 C3 0719 A 9110683U IDLER POST 3 Y 26 C8078A 9105500V RUBBER FOOT 2 Y 27 E0376A 9105808R BUSHING SHORTY 19ID A R Y 28 E0384A 9103764M SPACER M4 x 12 HEX 20 Y 29 E0446A 9105798F RIBBON CLIP RICHCO TC 30 1 A R Y 30 E1061A 9103826B BEARING 8 x 16 x 5mm 1 Y 31 E1078A 9103835L BEARING FL 8 x 22 X 7mm 1 Y 32 E5071A 9104133W PIN DOWEL 3 x 14 m6 1 Y 33 F0 0074 A 9120943G PULLEY ASSEMBLY 3 Y 34 F1 0450 A 9110684V PULLEY 32T XL 1 Y 35 F1 0454 P 9110681S PULLEY 24T x 3 8 HTD3 1 Y 36 F4 0293 A 9109978K PULLEY 40T x 22mm 1 0M 1 Y 37 P2414A 9110685W SPRING COVER POST 2 Y 38 C2 1134 A PIVOT HOUSING 1 N 39 P2065A 9106018K LATCH SPIGOT SHORT 1 Y 40 P2247A MODULE LOCATION SPIGOT 1 Y Fixings 50 E2793A SCREW M3 x 25 SKT CAP HD 1 51 E2826A SCREW M4 x 8 TORX PAN HD 33 52 E2828A SCREW M4 x 8 TORX CSK HD 6 53 E2 0840 A SCREW M5 x 10 TORX PAN HD 3 54 E2 0861 A SCREW M5 x 20 TORX PAN HD 4 55 E2534A SCREW M5 x 25 SKT CSK HD 2 56 E2504A M5 NYLOC NUT 4 57 E4048A M4 WASHER FORM C 1 58 E4012A M5 WASHER FORM A 4 59 E4033A WASHER WAVED W61370 SPEC 3 60 E5073A 9 5mm E CLIP 5 See fixing kit A0 0603 A 9110706T for this assembly Note Fixings are not available indi vidually 4 3 Chassis Assembly A2 1406 A Drive side Page 4 8 Issue 4 Apr 2013 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL D S Su pa LO LEQ HD
51. R NER S 3 6 3 9 Removal of Casse 3 8 3 6 Removal OF 3 10 3 7 Setup and Adjustments nnn 3 13 ao xa Yeh a kas 3 16 3 9 Recommended Spare Parts List 3 25 4 Exploded VIGW uuu ERa 4 1 4 1 Cardfolder Main Assy A5 0182 A nn 4 2 4 2 Chassis Assy A2 1406 A Operator Side 4 4 4 3 Chassis Assy A2 1406 A Drive Side 4 7 4 4 Chassis Assy A2 1406 A Output 4 9 4 5 4 11 4 6 Fold Wing Infeed A2 1408 A 4 13 4 7 Fold Wing A2 1409 A nnne 4 15 0 Cas sO A 4 17 4 9 Cardmailer 3331 TEE drrrEY Ts 4 19 4 10 Cardfolder A3326A N 4 20 Cardfolder III Service Manual Issue 2 Dec 2012 Page Page ii 100 140 CARDFOLDER III SERVICE MANUAL Electrical and CIFCUIES 5 1 5 1 Locations of Electrical Items 5 2 5 2 Feeder Folder PCB 180 785 Circuit Diagram 5 4 5 3 Stepper PCB 180 769 Circuit Diagram
52. S 6 xn IZH QNS PA diapz L Z og 5 qun JS gl vv g dIAG SL LL E 1N38n2 2 eL 6 mE Ass Tb z ord v 13H dot 334A 31 eau 8IN05 3 _ 81N Lora z VINOD TYO Z Z My E INYO sza L 9Lsve 4 HNVO 01 MOI olsa gt valir 992 98 ogo PLOHPL ALt 2 aL 9 86H 25 x 3 L Ut Z N iama 2 75 s gt 2012 tco 952 707 z 8 zn 8 440 NO 915 agen ZLLY 99 rza 9 LNOA Nat Al S l anyo Loszozevod SIM SAL OBETAT ven gg QNO O en L S 07 YNO XM LNVO 2 v 9 NWO l SM axi HNVO E XLINVO 2 7 HNVO En m DOA SM v 47 8 Z VNV LAO 2 95 e 9 SEP E e LUNO 55 ra VLen SLZOHPL HD p 2 olsy M 300 O daS Z SS LL 0630 SS va3s 863 468 Q 30 3a 6 6L id 8b 4g I YO QZH 9 90 9g 91 897858 HHNO SL cy sq tt 51 gano 301 301 Yno ZL D sq SL ta L Zuno x co d 5 VINO BSL 9814 22 0 GeO OLLY zb za 9 LANO S Ld Ld uoisubdx3 Lo i 07 4 ano g L Lely 10 6 L 99898 29 sol 22 Ler 0 eco ZOLM zivaan 4 Z x SOLM 0 L 895808 310d 4 t LOH L ML e 101 PAS mu ry 6 ZN CAS e 5 0 zed POLY ae 3
53. TEM If the values differ substantially from those Shown above the sensor is suspect d dd receiver voltage in volts If clear Should be approx 0 5v If blocked should be gt 4v 3 8 1 Display contrast C B clear or blocked Higher figures enhance contrast to darken Note depending upon unit fitted some display Default is 53 sensors may show receiver voltage only and whether clear or blocked 3 8 2 Module settings The following settings are available for the insert head and each track module num bered 1 onwards that is fitted and config ured All settings are described below These figures are read only prior to analysing them sensors should be auto calibrated and if any sensor fails it should first be cleaned and its connector checked Re calibrate and then replace if failure still occurs The figures may help in fault finding if failure still occurs contact PFE Technical Insert Head Support for further assistance b Analogue Sensors Digital 8 3 8 4 Digital Sensors gensaora P Calibrations This provides a read only display of whether the sensor is on or off If a sensor passes pese auto calibration but still gives errors the paper may be at fault due to transparency P Drivers Confirm by inserting a piece of the paper gt Motors between the sensor halves to check that it bInterlacks amp Covers passes from clear to blocked Also remove strong external light sources Se
54. TORX PAN HD TT M4 NYLOC NUT WASHER M4 FORM A WASHER M4 FORM C 9 5mm E CLIP SPRING OMR SHAFT SPRING LATCH RH SPRING LATCH LH BRIDGE CLAMP FOOT PUSH IN HEYCO 0862100 LOOM EMITTER 300 XH Qty Spares NJ E 1E RONA AN 00 L H lt lt lt m ou Z Z Z Z Z lt UU Z Z Z Z Fixings marked are not available separately order Fixing Kit A0 0605 A 9110708V Page 4 14 4 6 Fold Wing Infeed A2 1408 A 9110667C Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL 4 7 Fold Wing A2 1409 A 9110668D Cardfolder III Service Manual Issue 1 Nov 2010 Page 4 15 Item Part No 100 140 CARDFOLDER III SERVICE MANUAL Description Qty Spares 1 B2 1522 A FOLD WING UPPER 1 N 2 B2 1523 A FOLD INDEXING PLATE 2 N 3 B2 1524 A FOLD EXIT GUIDE 2 N 4 B2 1793 A COUNTERWEIGHT BRACKET 1 N 5 B2 1794 A COUNTERWEIGHT 3 N 6 B2 1850 A FOLD WING LOWER 1 N 7 B2 2066 A 9110697 FOLD WING RAMP 1 Y 8 C2 1026 A 9109973E GEAR CONNECTOR 1 Y 9 C4 0553 A SHAFT FOLD PIVOT DR 1 N 10 C4 0567 A SHAFT FOLD PIVOT OP 1 N 11 C8 0213 A 91105207 FOLD ROLLER 2 Y 12 E0367A 9103789N WASHER WAVED 23mm ID 4 Y 13 E1061A 9103826B BEARING BALL 8x16x5mm 5 Y 14 E1078A 9103835L BEARING FL 8x22x7mm 5 Y 15 E2509A SCREW M4 x 8 SKT CAP HD 3 N 16 E2535A SCREW M4 x 8 SKT CSK HD 6 N 17 E2830A SCREW M4 x 12 TORX PAN HD TT 1 N 18 E4033A 9104072H
55. VL a e ddlScd4 kk SLLOIN jen den 64 T x DOA OML Old YLIOHTL VLOHPZL Lv dalSld4 OS VLLOW don Von 88 Lg DOA ee e e 1 8 S e 6 8 e 8 ale 7 L 9 9ldl 9 E S 1 Pdl e 11 _ dl dl dl y GNOW e e e e vl 10 HcCLON 6 VoLOW gow s 67 A _ VLLOW LLIN _ S 86 e 1 e LE e AddSd L 97 223 L83AO9 gd3S Sd HOZZ TH 6 GZ d e JOcc H AddZd vd3S ASIGUWO Zd os Add d AYXGOld G ez MSIGUWO Zd Old 11 Add6d Zz 3 6d ee E ee 04169 NOS IS _ Hdi ddlScd4 JJA gt 2A did 8 did 9 g 6 dl Si Lidl 7 OL dl tlldl 9 m dl S ZL dl bdL m el dl c vl dl lal z dl 60LdL L dl cS LS v1G84Od gt 44 ev eh
56. allowed to dispose of the waste equipment via other waste streams but we encourage you to actively contribute to the success of such collection and to the common good and better quality of life of present and future generations For more information on the correct disposal of this product please contact your local dealer Cardfolder III Service Manual Issue 1 Nov 2010 Page 3 3 100 140 CARDFOLDER III SERVICE MANUAL 3 2 Conventions used in this Manual 3 2 1 Symbols Draws to your attention a particular difficulty associated with this Disconn operation or indicates a potential hazard with it being wi Indicates a piece of advice tip or quick technique to assist in carry Cg Remem ing out this operation complet 3 2 2 Orientation Throughout this manual reference will be made to Operator and Drive side to indicate the side of the machine in question These are defined as Operator Side The side of the machine where the operator normally stands viewing the screen The side covers can be opened by the operator Drive Side The opposite side to the Operator side The side covers cannot be opened by the operator and are only able to be removed by the Engineer Gear drive trains are located on this side Page 3 4 Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL 3 3 Information for Engineers 3 3 1 Service Procedures and adjustments The procedures described on the follo
57. definition and select one of the available templates either an unused one for creating a new defintion or an existing one for editing ENGINEER P Burn in Mode IN Env Only Mode IN D Set Default Supervisor PIN D View throughput P Sensor Cal Super D CONFIGURE SYSTEM P OMR definition KBCR definition OMRIA BCS1 You can now make required selections from the template BARCODE BCS 1 b Machine control BCS si gt Symbology 3019 D Characters in label a 5 gt Grouping End of group P Form seq start count 3 gt Form seq count dir P Group seq start count Ya 5 P Group seq count dirncrement f FS Note A full description each mark can be found in the Barcode Specifications docu ment for 100 140 Series Machine control Options are BCS CUS TOMER ID NEOPOST 3 LAST PAGE this is for legacy use only Symbology Only 3 of 9 is available at first release 2 of 5 and Code 128 on later ver sions Characters in label Up to 25 Grouping Options are End of group First of group Form or Group seq start count Options are 0 or 1 Cardfolder III Service Manual Form or Group seq count dir Options are Increment Decrement Customer ID start pos Selectable up to a maximum of the label length Customer ID length Selectable up to a maximum of the label length When all selections are made s
58. e to these rollers is by gears in mesh with a compound pulley gear which is driven via a series of 2 belt drives by either of a pair of wrap spring clutches one acting clockwise the other counter clockwise This compound pul ley gear also carries the armature of a friction clutch that is mounted on the cassette pivot shaft The cassette is driven by a stepper motor to rotate it either clockwise or anticlockwise A sensor flag is mounted on the shaft which passes through 2 slotted disc sensors diametrically opposed to monitor the cassette position for stopping and starting the stepper motor Cardfolder III Service Manual Issue 1 Nov 2010 Page 2 5 100 140 CARDFOLDER III SERVICE MANUAL Mounted on each side of the cassette are 2 semicircular shoes These have pressure pads bearing on them 2 positioned on the topside 2 on the underside These arrangements are to grip the document as the cassette rotates holding it in a consistent position prior to folding A long range cassette exit sensor is mounted above and below the cassette on the same shaft as the semicircular shoes The drive into the Fold 2 sub module is from the rollers on the Fold 1 sub module 2 2 6 Fold 2 Operation The friction clutch acts to lock the input drive and hence the feed rollers to the cas sette Therefore with clutch off the input drive will rotate the fold feed rollers either clock wise or anticlockwise depending upon whether the cassette is up or down
59. ed For standard or dual feeders leave these options unselected When finished select Continue to move to the next module 2 Plate Folder Module 2 bb OMR readers P Barcode readers P Daily Post Fitted gt Continue If the unit is reading OMR or Barcode select the number the of readers up to a maximum of either 4 x OMR or 1 x Barcode readers If the Daily Post option is fitted tick this box When operating the machine will then wait for manual insertion of forms in the handfeed tray When finished select Continue to move to the next module Cardfolder Module 4 Ch 8 Rdr PCh 10 Rar None ej Standard gt Online interface b Continue Select if an online interface is fitted allowing the cardfolder to be automatically fed from a card processing device Page 3 20 Issue 1 Nov 2010 Select number of OMR or Barcode readers fitted if applicable For Online Interface select Standard or Std Inv Bsy the opposite depending on signal supplied by card processor For Standard green LED on interface PCB is on when busy Std Inv Bsy is opposite Red LED indicates cardfolder disabled or unavail able for both Standard and Std Inv Bsy When finished select Continue to move to the next module 3 8 18 Licence set up Important this section must be read in conjunction with the OMR or Barcode Specifications document for 100 140 Ser
60. ee Fig 12 below ENGINEER Fig 12 2 As each clutch or brake is P Display contrast 53 5 switched on the relevant rollers gt Module Settings Module should rotate D Burn l Foldplate 1 clutch brake controls b Env Analogue Medule 2 the feed rollers just before the fold P Set I plate P View set i Cassette In Out feed controls the 2 pow pairs of feed rollers in the cassette gt CON gt Driv Main Motor nn In feed is ACW rotation viewed IP Mot Clutch Infeed from operator side out feed is ieee IP Brake Infeed CW Isis IP Clutch Foldplate 1 Brake Foldplate 1 b Brake cassette IP Cassette In feed Cassette Out feed Cardfolder III Service Manual Issue 1 Nov 2010 Page 3 13 100 140 CARDFOLDER III SERVICE MANUAL 3 7 3 Fold Types 1 To move the address position select Adjust address at the end the calibration cycle ve moves the address up ve moves it down The effects of this can be seen and if necessary adjusted by editing the mailpiece EDIT TAS Fig 13 2 Select Edit Item View Fold Type Advanced as shown in Fig Edit 2 p Edit Item gt A4 i gt View Job Feed 1 Se CARDCARRIER ITEM 2 Depending upon the fold type the gt Sab Address screens shown below will display P Address P a ITEM 2 the settings and allow adjustment Psi P Length A if required Caution it
61. elect Done and you will move to Edit Label Example for BCS EDIT LABEL BCS 1 b Grouping Char Pos Selects Item 1st Char Pos Selects Item No of Chars n 9 gt Divert Char Pos P Form Security Char Pos Group security Char Pos D Matching Char Pos Done Example for Neopost 3 EDIT LABEL BCS 1 Page N of M Disable Page N of M chars Tal gt Sheet Seq Disable P Sheet Seq chars n Tal gt GroupSeq Disable Disable P GroupSeq chars Insert gt Accumulate Note that for machine control Customer ID there is no edit screen as no other charac ters are used Make selections as required to define each character position number of characters if using BCS or the state Enable Disable Ignore if using Neopost 3 When all marks are defined select Done Issue 1 Nov 2010 Page 3 23 100 140 CARDFOLDER III SERVICE MANUAL 3 8 21 Naming the job After editing the marks you move to the Save screen which allows you create a new name for a new definition or simply press x if editing an existing one you will be asked to save before exiting the edit mode NEW NAME ah To enter a new definition name use the Scroll Up Down buttons to select the first character then press v This moves to the second character and so on up to the max imum 10 characters When finished press x to exit the screen Confirm your changes
62. en using the CF module acts as a slave to the feed machine waiting for and reacting to an incoming document The system will wait ready indefi nitely but will shut down the drives after a short time out until the entry sensor is blocked If the CF module is not selected in the software then the remaining modules of the folder inserter will perform as normal There is a signal interface from the CF to the feed machine that provides 2 signals e System Ready Fault a status signal which can be displayed on the feed machine control e Busy Ready to receive inhibits the feed machine if not clear to 1st hold point There is no feedback from the feed machine Page 2 2 Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL 2 2 Cardfolder Sub Modules There are 3 functional sub modules within the Cardfolder Infeed Fold 1 amp Fold 2 The main drive is by a motor within the Cardfolder which drives the various constantly running rollers conveyor and clutch inputs via various belt amp gear drives There is a Slotted disc amp sensor monitoring the main drive The cardfolder utilises the same PCB as a standard feeder although has unique firmware 2 2 1 Infeed Description see Fig 2 M L x oO O NG dD Paper path
63. g off at the mains Always disconnect the machine from the mains source before removing covers Don t just switch off Ensure the black inner covers on the operator side are in place when work is finished These covers protect the operator from hazardous areas when the cover is opened When removing items such as the envelope feeder assembly note that some items are very heavy and lifting should not be undertaken unless you feel confident to do so Seek assis tance otherwise Cardfolder III Service Manual Issue 1 Nov 2010 Page 3 5 100 140 CARDFOLDER III SERVICE MANUAL 3 4 Removal of Covers Some or all of the covers on the machine will need to be removed for service operations In some cases where fixing screws are plainly visible removal is self explanatory In less obvi ous cases removal is described below When service operations are complete covers must be replaced fully failure to do so could result in a hazard to the operator Note that when a cover is opened magnetic reed switch interlocks will prevent the machine from operating 3 4 1 Drive side cover The cover is retained by 2 x M4 screws and a hooked return on the lower edge Remove the screws indicated below and drop the cover slightly to free the lower edge When replacing ensure the hooked return is properly located A 3 4 2 Drive side skirt After removing the drive side cover the lower skirt can be removed by taking out the 6 x M4
64. he document will enter the cassette its leading edge moni tored by the cassette entry sensor It passes through the cassette exit sensor and continue for a distance according to the selected fold length the remaining portion of the document will then still be in the feedpath outside the cassette The document will be stopped and the cassette will rotate 180 clockwise or anticlockwise as described in Fig 7 below this point can be used as a hold point in the event of an up stream hold up see Fig 7 below Fig 7 If all is clear after a short delay the feed rollers will restart moving the partially folded document into the nip of the fold rollers which completes the fold and transfers the document out of the cardfolder The next document can now feed into the cassette and the process repeats Cardfolder III Service Manual Issue 1 Nov 2010 Page 2 7 100 140 CARDFOLDER III SERVICE MANUAL Page intentionally left blank Page 2 8 Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL Section 4 Exploded Views Sect Page 4 1 Cardfolder Main Assy A5 0182 A 4 2 4 2 Chassis Assembly A2 1406 A Operator Side 4 4 4 3 Chassis Assembly A2 1406 A Drive Side 4 7 4 4 Chassis Assembly A2 1406 A Output 4 9 4 5 Infeed A2 1407 A 4 11 4 6 Fold Wing Infeed A2 1408 A 4 13 4 7 Fold Wing A2 1409 A 4 15 4 8 Cassette A2 1410 A 4 17 4 9 Cardmailer BCR Kit 4 19 4 10 Cardfolder BCR K
65. ibrations Use if the set tings need to be different from the calibrated sizes Wetter Start Adjusts the point at which the wetter beam drops to wet the flap ve more wetting In steps of 1mm Note this setting ap plies to the machine and can be fur ther adjusted for the job in Advanced Wetter Stop Adjustment of the point at which the wetter beam lifts ve more flap length is wetted In steps of 1 Note this setting applies to the machine and can be further ad justed for the job in Advanced Envelope Stop Position Cal Adjusts envelope stop position Positive fur ther forward towards exit direction Envelope Insert Position Cal Adjusts amount of insertion of insert pack into envelope Positive further forward past flap crease Envelope Reverse Position Cal Ad justs amount of envelope forward travel after flap wetting before revers ing to enter sealing rollers Positive further forward into rollers towards exit direction Envelope Seal Position Cal amount of envelope travel into seal rollers Posi tive further forward away from exit direction Issue 1 Nov 2010 Page 3 17 100 140 CARDFOLDER III SERVICE MANUAL Envelope depth Measured automeas ured depth of envelope which will be displayed Adjust up or down to suit actual envelope size Positive great er Envelope flap Measured automeas ured flap length of envelope which will be displayed Adjust up
66. ies Entering the licence key This procedure assumes that the licence key has already been obtained This key must then be entered into the software before an OMR or barcode definition can be created Enter Engineer mode and select Licence Set up ENGINEER gt Module Settings Insert Head b Burn in Mode Env Only Mode Set Default Supervisor PIN gt View throughput LIE LIIS Sensor Cal Super gt CONFIGURE SYSTEM b Licence Set up Select Enter Licence Key LICENCE gt Machine ID BN3Q UM 4 DAA p Enter Licence Key Feature Set D 0000 0000 0000 P Update Machine ID Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL This will allow the key to be entered as Shown below LICENCE To enter the licence key use the Scroll Up Down buttons to select the first character then press v This moves to the second character and so on up to the maximum 10 characters When finished press x to exit the screen When the conformation screen appears press v to exit You should now see that Feature Set is no longer shown as zeroes see below The number will reflect the licence entered and is generated by the software The types of licence available are e BCR Flex up to 9 OMR Flex up to 9 e BCR Adv 1 only e OMR Adv 1 only e OMR T always applies e MPPC 1 only LICENCE P Machine ID b Enter Licence Key 0 43
67. it 4 20 Cardfolder III Service Manual Issue 1 Nov 2010 Page 4 1 100 140 CARDFOLDER III SERVICE MANUAL 3 1 Health Safety amp Environment 3 1 2 Safety instructions 3 1 1 1 General e This machine must be operated by competent personnel The manufacturer accepts no responsibility for accidents or injuries caused by opera tion by incompetent personnel e Covers may only be opened by skilled persons who know the risks involved For safety reasons the machine will not function with opened covers e Keep away long hair fingers jewelry etc from rotating and moving objects of the system e Switch off the system at the end of the day 3 1 1 2 Electrical safety e Disconnect the mains power supply before performing any maintenance to any kind of mains power supply high voltage related items e he power connection must be easily accessible preferably close to the machine e For safety reasons it is essential that the machine is connected to a socket outlet with protective earth connection e Over current protection in the equipment also relies on the branch circuit protec tion e Disconnect the machine from the power supply when it is not in use for a longer time e Potential hazard may exist to electronic hardware in conditions with static electric ity It is advised that when handling electronic parts an earth connected wrist band is used in order to be permanently discharged from static electricity 3 1 2 End
68. ket and foldplates For Card folder foldplate 1 amp 2 stepper motors are tested both forward and reverse directions Note that foldplate 2 cassette motor will also test the proper function of the cassette Home and Away sensors Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL 3 8 10 Interlocks amp Covers Reports on state open or closed of covers and interlocks feed trays present for each unit Use this to test for deficient switch or magnet 3 8 11 Burn in Mode If this is selected when Engineer mode is exited and the machine is run it will operate indefinitely using the last selected job Re move all stationery first Switch to another job if required and burn in will then operate with those job parameters Note that burn in does not increment the total machine count 3 8 12 Env Only Mode Allows machine to run with envelopes only to help fix envelope problems 3 8 14 Set Default Supervisor PIN Allows the Supervisor PIN to be set to its system default of 123 Use this feature if the Supervisor PIN has been changed and then forgotten The PIN is changed by the user in Supervisor menu 3 8 13 View throughput If deselected suppresses output per hour rate on display when running Use when conditions require output rate not to be shown 3 8 14 Sensor Cal Super If selected adds analogue sensors to Super visor menu to allow calibration Cardfolder III Service Manual
69. may be IZE possible to enter settings that ins w 102 19 the machine cannot process Width vance alf gt Feed Coub Done D Fold Type b View Fold 7 Fold A Top address Face up e Feet first B b Length A p Plate 1 mm gt Length B n gt Fold 1 direction up e gt Advanced Plate 2 mm 02 5 Done D Fold 2 direction CCw Done 7 Fold A Top address Face up tw Feet first B N OM of CA Fig 14 Fig 15 Settings for Z Fold Top Address Settings for Z Fold Top Address View Settings window Advanced window cont Page 3 14 Issue 1 Nov 2010 Cardfolder III Service Manual FOLD ITEM 2 b Length A Length B D Advanced Done 7 Fold B Bottom address de on Face up het Feet first AN Fig 16 Settings for Z Fold Bottom Address View Settings window FOLD ITEM 2 D Length A Length B b Advanced Done C Fold Top address sE Face up p Feet first Fig 18 Settings for C Fold Top Address View Settings window FOLD ITEM 2 P Length A Length B Advanced Done w Fold A Top address Face up SAN Feet first p Fig 20 Settings for V Fold Top Address View Settings window Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL FOLD PLATES ITEM 2 plate 1 mm P Fold 1 direction P Plate 2 mm Fold 2 di
70. nsors loca tions are described on the following page Note some sensors may differ from those shown depending on unit configuration Insert Head Env Deskew in front of pickup rollers centrally located Env Flap on bracket below env hop per open front cover to access Fingers Out on RH side at the end of the finger arm Pawl Position below env hopper in RH chain track open front cover Page 3 16 Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL Wetter Home on RH side below disc Fingers Datum amp Side Fingers Disc withdraw finger assy to access Side Guide Datum on RH side in front of Lenze clutch Side Guide Disc just behind side guide datum sensor Main Disc on RH side next to env hopper Feeder Seprtr A amp B visible through chassis cutout on LH side on separator slide Open side cover to access Main Disc encoder on motor drive disc on RH side Dual Feeder Hopper 1 Seprtr A amp B on separator Slide Remove cover below hopper to access Note that Hopper 2 Sep sen sors are analogue Main Disc encoder on motor drive disc on RH side 2 Plate Folder Main Disc encoder on motor drive disc on RH side Cardfolder FP1 FP1 Home pos FP2 Home pos Main Disc all located on drive side chassis Cassette exit located on pressure shoe pivot bars 3 8 5 Calibrations CALIBRATIONS 0 p Set Pocket to 210mm P
71. o that there is no perceptible play but do not overtighten Fig 10 on the following page shows the route of the main drive belt Cardfolder III Service Manual Issue 1 Nov 2010 Page 3 11 100 140 CARDFOLDER III SERVICE MANUAL Fig 10 Showing route of drive belt Page 3 12 Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL 3 7 Setup and Adjustments The following adjustments may be needed if the machine has processed a large number of items or if operating problems are occurring 3 7 1 Pressure block adjustment 1 The pressure blocks operate on the cassette drums and hold down the folded panel of the second fold the upper shoes control anti clockwise rotation when viewed from operator side the lower blocks control clockwise rotation If the pressure is too heavy inconsistent folds lengths can occur 2 For each block slacken the 2 screws indicated and turn the collars to tension or slacken the Springs as required To adjust the lower shoes the Cardfolder must be separated from the inserter to gain access from the front Important the blocks must be adjusted to equal pressure or skewing may occur 3 7 2 Engineering Drivers 1 This allows the clutches and brakes controlling foldplate 1 and cassette and also the main motor to be tested by switching them on The main motor can be set running while clutches and brakes are operated though some cannot be operated in unison S
72. of life The objectives of the European Community s environment policy are in particular to pre serve protect and improve the quality of the environment protect human health and uti lise natural resources prudently and rationally That policy is based on the precautionary principle and principles that preventive action should be taken that environmental damage should as a priority be rectified at source Separate collection of waste is the precondition to ensure reuse and recycling of waste that is generated at the disposal of electrical or electronical equipment and is necessary to achieve the chosen level of protection of human health and the environment in the Euro pean Community More particularly certain materials and components of waste electrical and electronical equipment needs selective treatment as their injudicious handling or disposing of on or into land water or air would represent a major threat to the environment and human health cont Page 3 2 Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL In order to facilitate collection and treatment separated from normal domestic waste electrical and electronical equipment is marked with the following logo Do not mix with normal domestic waste Please use the subjoined return or collection system dedicated to electrical and electronical waste Equipment produced after August 13 2005 Not only are you by law not
73. older III Service Manual Issue 1 Dec 2012 Page 4 20 100 140 CARDFOLDER III SERVICE MANUAL Section 5 Electrical and Circuits Sect Page 5 1 Locations of Electrical Items 5 2 5 2 Feeder Folder PCB 180 785 Circuit Diagram 5 4 5 3 Stepper PCB 180 769 Circuit Diagram 5 6 5 4 Cardfolder Interface PCB 180 789 Circuit Diagram 5 7 5 9 Long Range Sensor PCB 180 790 Circuit Diagram 5 7 5 6 Cardfolder I F PCB 180 8436 Circuit Diagram 5 8 9f Cardfolder PSU 184 2351 Wiring Diagram 5 9 5 8 Machine Wiring Diagram 5 10 Cardfolder III Service Manual Issue 1 Nov 2010 Page 5 1 100 140 CARDFOLDER III SERVICE MANUAL 5 1 Electrical Items Locations Shown below are electrical components and sensors used on the Cardfolder III See following page for items list 7 23 27 28 3 22 4 26 29 8 10 37 14 11 32 33 20 19 17 12 1 30 31 9 21 15 33 34 13 24 25 6 18 Page 5 2 Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL 5 1 Electrical Items Locations cont Ref Part No Description Qty EC30 Clutches 1 179 109 CASSETTE FORWARD REVERSE FEED CLUTCH 1 2 179 110 HOME OUTFEED CLUTCH 1 3 179 110 FOLPLATE 1 FEED CLUTCH 1 4 179 110 INFEED CLUTCH 1 5 179 110 INFEED BRAKE 1 6 179 110 FOLPLATE 1 FEED BRAKE 1 PCBs 7 180 759 PCB SPLIT 5SEN 5SOL H D 1 8 180 760 PCB SPLIT 3SEN 4SOL H D 1 9 180 769 PCB ASSY AM4 STEPPER 2 10 180 785 PCB ASSY AM4 TWR FEEDER 1 11 180 789 PCB CARDFOLDER INTERFACE 1 12 180 790 PCB
74. on of the DIP switch for Cardfolder or feed unit is shown in Fig 4 below Note that the machine can be configured only up to 4 modules DIP switch Cardfolder PCB Comms lead Terminator 3 Check machine package label on each unit for correct product codes and software compat ibility eg Software Level V5 1xx must be on ALL units The first two digits must be the same for compatibility the second two can be different Fig 5 Comms connector Terminator positioned closest to PCB surface 4 Connect the units together with the Com ms leads plugged from one PCB to the next as a daisy chain On each unit the lead is plugged into one half of the PCB connector and coiled inside the unit Locations of the connec tors are shown in Figs 4 and in Fig 5 showing the Control PCB in the insert head Note Comms lead for inserter 160 511 is longer tha feed unit leads 160 510 which are all identical AM4 Control PCB a 4 Check the T101 terminator link 182 557 is fitted on the insert head and last feed unit PCBs see Figs 4 amp 5 Note that there are two connector positions on the control PCB the link is fitted closest to the PCB surface Cardfolder III Service Manual Issue 1 Nov 2010 Page 1 5 100 140 CARDFOLDER III SERVICE MANUAL 5 Starting from the last feed unit on the machine Cardfolder connect the power leads from each module to the one
75. or down to suit actual envelope size Positive greater Ins Pawl Stop Position Cal Adjusts stop position of insert pawls behind in sert pack in collate pocket If the pawls are stopped too high by the software inserts entering the collate pocket will contact the tips hence position must be adjusted back Posi tive further forward Pocket Backstop Cal As inserts en ter the collate pocket they contact a backstop to prevent overrun and stop The backstop is then lowered and the insert drives forward This setting in creases the time delay before the insert drives forward Use if backstops are slow to drop for any reason caus ing crashing If set to Off backstop remains lowered always Feeders dual only Collate Feeder 2 Cal Moves the form in hopper 2 to adjust collate point Positive further forward in steps of 1mm 2 Plate Folder Folplate 1 2 Cal amp No Fold 1 2 cal These are the same as 1 amp 2 of the 3 Plate folder see below Cardfolder SETTINGS 3 Up Cal fi 4 Down Cal n 5 D FP2 Clockwise 14 Counter CW Cal 1 13 p ie 1 5 DFP 2 Clockwise Delta DFP 2 Counter CW Delta These settings all adjust how far the paper moves into foldplate 1 or 2 cas sette as monitored by the leading edge from Foldplate 1 sensor or Cas sette exit sensor Units are in mm Page 3 18 Issue 1 Nov 2010 FP1 Up Down Cal Fold type
76. otating ED Fig 4 On the drive side check that the indicator mark on the flag aligns with the mark in the centre of the sensor If not slacken the 2 outer screws and adjust the flag as required After retightening ensure it has not moved Remove the screws inserted in Fig 4 Cardfolder III Service Manual Issue 1 Nov 2010 Page 3 9 100 140 CARDFOLDER III SERVICE MANUAL 3 6 Removal of Fold Rollers There are two pairs of fold rollers in the machine uncoated rollers on Foldplate 1 and coat ed rollers in front of the cassette for the second fold The following procedure describes the removal of either pair Rollers will need to be replaced if they incur ragging or deposits that cannot be removed by normal cleaning Fold Plate 1 Rollers 1 Remove both side covers from the feeder section 3 4 and open the perspex top cover 2 With the fold plate in its down home po sition remove the 2 screws each side secur ing the fold exit guides see Fig 6 3 Rotate the fold plate as far as it will go and from above spring the side plates slightly to remove the 2 fold exit guides Fig 7 shows the fold plate after removal of the guides Note if the bridge clamps come loose these can be pressed back into position upon reas sembly 4 Rotate the fold plate back to its home po sition and remove the gears flanged bearings and wavy washer from both fold rollers D Lift the fold rollers out from below
77. r 2013 Operator side Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL 7 45 zo lt b LO sp LO i d pe SA SS amp SS on O66 558 ANA ae amp Aa od o Fap 18 40 51 57 4 3 Chassis Assembly A2 1406 A Drive side Cardfolder III Service Manual Issue 3 Apr 2012 Page 4 7 100 140 CARDFOLDER III SERVICE MANUAL Item Part No Description Qty Spares 1 169 128 9108602B RIVET 4mm 3 5 4 5 GRIP A R Y 2 169 140 9100466B CLIP RESTRAINT SMALL A R Y 3 169 144 9110677N CLIP 34W RIBBON CABLE A R Y 4 169 146 9105790X RIVET 3 5mm 2 7 3 6 GRIP A R Y 5 N A 6 180 759 9100744R PCB SPLIT 5SEN 5SOL H D 1 Y 7 180 769 9100751Y PCB ASSY AM4 STEPPER 1 Y 8 180 776 9100753A PCB WIDEBODY DISK SENSOR 5 Y 9 180 785 9105209S PCB ASSY AM4 TWR FEEDER 1 Y 10 180 789 9108026B PCB CARDFOLDER INTERFACE 1 Y 11 180 790 9105270F LONG RANGE SENSOR PCB 1 Y 12 180 794 9105271G PCB ASSY PHOTOLOGIC DISK 1 Y 13 180 8436 9110682T PCB ASSY CARDFOLDER I F 1 Y 14 181 018 9100760H MOTOR ASSY STEPPER 1206 1 Y 15 B2 1538 A CHASSIS SIDE PLATE DR 1 N 16 B2 1542 A MOTOR PLATE 1 N 17 B2 1545 A CLUTCH LOCATOR 2 1 N 18 B2 1547 A PCB PANEL 1 N 19 B2 1565 A LOWER PANEL OUTFEED 1 N 20 B2 2138 A WIRING BRACKET 1 N 21 G4 0149 A FOOT SPIGOT 2 N 22 C2 1026 A 9109973E GEAR CONNECTO
78. rection cw 2 2 1 OF CNA OF Fig 17 Settings for Z Fold Bottom Address Advanced window FOLD PLATES ITEM 2 p Plate 1 mm D Fold 1 direction gt Plate 2 mm D Fold 2 direction C CW E Done 2 1 OF QNA OF Fig 19 Settings for C Fold Top Address Advanced window FOLD PLATES ITEM 2 p Plate 1 mm D Fold 1 direction D Plate 2 mm Naot Used 5 Fold 2 direction 2 1 OF CNA OF Fig 21 Settings for V Fold Top Address Advanced window Issue 1 Nov 2010 Page 3 15 100 140 CARDFOLDER III SERVICE MANUAL 3 8 Engineer Mode Engineer mode can only be accessed by in 3 8 3 Analogue Sensors put of the correct PIN It allows the engineer to test the machine functions and configure the system to reflect the machine hardware abc d d Cor B and options The meaning of the numbers is as follows These are shown in the format a emitter current value 0 9 ENGINEER b receiver pot setting value 0 9 Display contrast Both a b are mostly of use only to Module Settings Insert Head gt Technical Support for fault checking in PBurn in Mode _ combination with other parameters Env Only Mode c threshold voltage value 0 9 P Set Default Supervisor PIN Should be approx 4 5 View throughput gt Sensor Cal Super gt CONFIGURE SYS
79. rizontal OMR marks Pitch Options are 3mm 3 8mm 4mm 5mm 5 3mm 10mm 1 10inch 1 8inch 1 6inch 1 5inch 1 Ainch 1 3inch Parity Options are None Odd Even Form seq start count Options are O or 1 Refers to both Form sequence within a job and Form sequence within a group Reverse seq order Select if marks are to be read backwards eg if paper is loaded the other way up Invisible gate mark Select if used An invisible gate mark allows a single mark Issue 1 Nov 2010 Page 3 21 100 140 CARDFOLDER III SERVICE MANUAL on the last page of a group to be used as an end of group mark Pitch will default to 10mm number of marks to 2 invisible gate and printed mark Other functions except Gate mark to indicate position will be null Applies only to 1 track Diverti and Divert2 Select event to occur if divert mark is used Divert2 applies to 2 track only When all selections are made select Done and you will move to Edit Marks EDIT MARKS OMH 1 gate blank blank e blank Make selections as required to define each mark as explained in OMR Specifications for 100 140 Series The points shown on the following page must be noted e Mark 1 is always the gate mark and cannot be changed e Marks are defined in print order not feed order e Marks must be defined in specific fixed order For PFE OMR marks the order is as follow
80. s Gate default Group EOG FOG Parity Divert No seal Select item 2 10 Sequence in Job 1 5 Sequence in Group 1 4 Force fold Auto end For Neopost 2 track OMR marks see the or der defined in Two track OMR Specification and Functionality for 100 140 Series When all marks are defined select Done Page 3 22 Issue 1 Nov 2010 Naming the job After editing the marks you move to the Save screen which allows you create a new name for a new definition or simply press x if editing an existing one you will be asked to save before exiting the edit mode NEW NAME To enter a new definition name use the Scroll Up Down buttons to select the first character then press v This moves to the second character and so on up to the maxi mum 10 characters When finished press x to exit the screen Confirm your changes and your new definition is now saved All OMR definitions created in Engineer mode will be available to the operator for selection when creating jobs that use OMR stationery Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL 3 8 20 Barcode Definition Creating a Barcode definiton allows the op erator to select it for use in a job setup Up to 9 definitions can be created depending upon the option chosen at machine pur chase The template for the definitions will have default name usually BCS 1 BCS 2 etc which can be renamed after defining Scroll down to BCR
81. wing pages are the recommended methods to be em ployed when removing or replacing various items Note that not all individual spare parts may be available for replacement in some cases only the assemblies containing those parts can be obtained For further clarification see section 4 3 3 2 Tools required No special tools are required for service operation on the machine though a variety of stan dard engineer s tools will be needed including e Torx drivers 10 15 20 25 e Pozidrive screwdrivers 1 amp 2 e Set of metric Allen Keys e Pointed snipe nosed pliers e Right angled bit drivers e Side cutters e In addition a stock of cable ties 100 x 2 6mm 169 102 3 3 3 Electrical Connectors and Sensors Sensors are supplied as a cable assembly with the sensor at one end and its two connectors at the other All sensors with the exception of flag or disc sensors consist of a pair Emitter and Receiver The receiver is usually mounted below the emitter though this can vary All connectors are marked with the number of the appropriate PCB connector to which it joins 3 3 4 Potential Hazards Take extreme care if running the machine with the covers open To run with the cov ers open a magnet will be needed to override the safety interlocks A spare magnet such as fitted to the opening cover 131 824 is most suitable The machine is double pole fused This means that power may still be present even after switchin
82. ze clutch cable from the splitter board 2 Remove the screw retaining the cassette pulley on the drive side Wind the belt off the pulley and lift off the pulley note the drive pin behind see Fig 1 Do not disturb the sensor flag on the pulley 3 Onthe operator side remove the bracket over the end of the cassette as shown in Fig 2 noting that the cassette will be released upon removal Note there is a wavy washer under the flanged bearing at each end of the cas sette shaft 4 Remove the pivot bar holding the upper cassette shoes the operator end locates in a D cutout in the chassis Take the belts off the end of the caasette assembly and lift it out of the chassis see Fig 3 showing the cassette just before final removal The caasette can now be stripped for mainte nence as required Page 3 8 Issue 1 Nov 2010 Cardfolder III Service Manual 100 140 CARDFOLDER III SERVICE MANUAL Reassembly of cassette Reassembly is a reversal of removal noting the following points e Ensure that the wavy washer is in place on each of the flanged bearings e When replacing the bracket on the operator side the tang on the Lenze brake must locate on the lug on the bracket e When reassembling the pulley the procedure described in Figs 4 amp 5 must be followed Temporarily lock the cassette to the chas sis side plate using 2 x M4 screws Do not overtighten this is just to prevent the cas sette from r

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