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INSERT HEAD Module - Neopost Technologies Ltd

1. SHAFT ADAPTOR 2 5 GRUB SCREW E257 1A DISC SENSOR PCR 160 659 3 5mm 169 145 E A 4 EST MAXEPOZIPANSCREW E2701A a M3 x 5mm CAP SCREW ae E23D4A s m p FINGER BRACKET SENSOR BRACKET 58652 PMID P E CLIP 77 FINGER DATUM SENSOR PCS 180 775 FINGER SET ASSEMBLY RIVET 3 5mm AT SEA 169 145 9 5mm E CLIP NOTE DATACARD FINGER l A ee eee ELENA Pu i 1 ET CHASSIS A7352A 1S IDENTICAL ATOS6A 5 FINGER FLA X 5 EXCEPT FOR FINGERS SEE BT435A SECTION 4a 38 SEARING 6mm CLIP DISC ASSEMBLY x D1076A 84330 Y 22 2 LEAD SCREW SET ASSEMBLY CITA 12 02 07 Page 1 29 Technical Tips INSERT HEAD Module FINGER STOP TT n 20 M4 x 10 POZI PAN HD SCREW E2519A FINGER BRACKET OP ae _M4 WASHER g 2 43 a 7 E4011A FINGER ARM PIVOT ed SD C3478A 2 7 FINGER ARM OP ASSY M a A B4332A M4 x 8 POZI PAN HD SCREW Ce d E2701A ar EL 2 em J WASHER E4009A 2 a CLUTCH PIN 0079 77 SPRING LINK i G1180A M3 x 5 SKT CAP HD SCREW E2804A FINGER SOLENOID 1 SPRING SOLENOID 181 142 1152 12 02 07 1 30 Technical Tips INSERT HEAD Module DEEP THROAT FINGER KIT A3325A FINGER PIN SPR
2. 1442 bin 3PF Pe v we x x m amp 143048 Head 145244 Tower Feeder 44344 FPF 3 Hopper 3 Plate Folder 1 Hopper 3 Plate Folder E HOCA comprises Automatic Foldset upf HN af sheets folded via accumulator 80 gsm tow d Accumulator Bedd x ET x m Ep Divet x Ef x m Ep El OMIR see OMA Features table below Mate 1 ia El ow gm m m m mE Bottom Read Barcode see Barcode features table below 1 F wo ow ow ew m Additional head A3261 amp note b E m m 3 Flate Folder OMAR Cascade see OMIR features table below k amp x x x gH wo ew DalyPaz HE gE of sheets folded via Daily Post 5095 3 8 2 a za a a 3 Plate Folder Turnover assembly Far Single Farms V Fald anl aw Jg m RE GU templates stationery OMA and Barcode Pow we Lx ew ew lo Self diagnostics at start up sensors solenoids and clutches Pow ew Lx vw ew lo Operator adjustable deskew setting Automated Application Set up Dynamic sensor monitoring constant checks during running ar sensors Supervisor access bo
3. 3 Eauelope zetip Ce rthger ze ze toomecth in the e width To ieztror ti mark the extreme edges ofthe exi rial tigers oa the chase bridge tiat zitagalirt zee Ngee 5 Fra ab envelope torgi tie sys m by band a dztop Itattke area The Tiger pce marks on the con thea be aged dp check thelr pozos re Bill the e These marks chow be equally spaced ithe rz ides tom the edge of the e The detauitrligerzettiing app Bi Tm m tom the edge or the aad cai be adi ced board eged I additio check mtke rt E TW ikr cue d by extreme z ofthe of ET Toe miae E open l q the ti roa torte e l fee Dy tan da d Yo wa d tom the start the postion Engage the Tigers mai eagles rand tke check Hrm HIF Tage rer ty sig the ok ofthe envelope Bed skk pated see 6 HOE the Tigers are sot Ippo rth Ope s lhg tie Midd ofthe ti nat az oa 22mm middle Tl G TE will require exte Calle packet widti E correct Tor e fie wideztdocame at iver onc Paced tie colate pocke tg liez Zmm cha O arest polit Ako 10 Flies Tu lig or Ek lier Atm willl ad azt he ome IT Tier pr D N ad irt are cke cs polit 3 aud ad
4. MaxiMailer to MaxiMailer Plus R38 150 EmerS7 Version 3 Sv supply low Oa C A39 1 0 PlugandPlaywithversion3 0905 A40 1 50 Roller Cleaning Fluid Wyo A41 1 51 MaxiMailer Software Firmware versions A42 159 Saving jobs 7 aa JanOo5 02 Envelope flap catches on the Sealer Ski B7464A when running in No Seal Mode A44 1 62 Envelope crashing at Reversing Closing A46 1 64 Plus PC Set up Instructions 4 A47 164 22222 EL fo 12 02 07 4 Technical Tips INSERT HEAD Module MaxiMailer Service Engineers Technical Tips Documentation Jan 2007 INSERT HEAD Module 1430 1431 and variants Technical Page Main Area INSERT HEAD Date Date Technical Mandatory Tip Number 1430 1431 and variants Effective Effective to Bulletins Number if applicable 12 02 07 1 5 Technical Tips INSERT HEAD Module MaxiMailer Service Engineers Technical Tips Documentation Jan 2007 Field Options Summary Table Part Relevant Application Qty Description Number Assembly required Number D0052A N A Jog Tyre M 2 2 off These tyres are standard on the envelope feed and JI Feeder fitted on are used to provide improved grip
5. Pin E5078A in Envelope or Insert feeder Pick up shaft is not working loose Loctite pin to prevent this from occurring 12 02 07 Page 1 39 Technical Tips INSERT HEAD Module A 22 Sealer Closer Assembly A7046A black tape fitted to prevent reflecting of metalwork Field Option There has been one instance of envelopes exiting the machine without closing the flap resulting in error 47 jam at output sensor Initially check by blocking clearing the closer output sensor analogue reflective sensor If the sensor stays blocked at the first instance try moving the machine away from light If this is not appropriate BLACK insulation tape can be fitted onto the closer overguide B7731A as shown below Black tape to be fitted 12 02 07 Page 1 40 Technical Tips INSERT HEAD Module A 23 AC Motor Fails to Stop on Opening of the Covers Problem resolved with firmware version V4 0 0 12 or V3 4 0 12 onwards effective from Feb 06 oymptom AC motor fails to stop on opening of the covers Please note that the solenoids and clutches are turned off and that the AC motor cannot be started unless the covers are closed Machines affected This may be a problem on any module including the head unit manufactured before June 2004 This equates to serial numbers GAZ or earlier Risk This is a risk to the engineer only not the operator The engineer is at risk if relies on the covers as an emergency switch for tu
6. orzimila x x x x x x x x F 1 1 1 1 1 1 1 1 MaziMailer Cardfolder 5 Cardfolder Barcode reading see Note 4 x ox og zheetaorinsert 3750 3750 3750 3750 3750 2750 3750 4100 k fo 12 02 07 Page 1 72 Technical Tips INSERT HEAD Module Features List of OMR or Barcode OMA Features End of Group Mlode group mark last page edif E m gm wm c First of Group Mode group mark onfirstpagefed El El m m m m m gm Farms Sequence within a job security Marks 0 63 El E E E gm gm m ve Group Sequencing within a group 4 Marks 0 15 E El gm gl gm gE gm v v v7 Face Down Split Groups based on Fold Setting HE gm gm gm mj Diverting all oversize groups see note 3 El E g amp gm gE gm gm ve v OMA Cascading on3PF happersiand2 x x Mm m mj j z 1 Selective Feeding of Folded sheets HE m gl g gm mij x x lt X X lt lt Selective Feeding of inserts gm m j a m a a Selectively Feeding hoppers can Feed multiples mJ a ma Divert group on Mark Mote 3 E
7. 4 There has been 1 instance of splashing due to excess wetting causing a problem with the Wetter Output Receiver S2 RX This sensor can be covered using clear vinyl tape E0422A request 0 5m only It should be re calibrated after fitting of the tape in Engineer mode run Calibrate all sensors in Analogue sensors 5 Over filling the Wetter reservoir will result in an overflow into the machine Ensure that the reservoir is not over filled when replenished with wetter fluid The operator should be trained as outlined in the Operating Instructions i e is aware of the Max Fill position NB The Wetter Reservoir and Wetter Tank MUST be drained before moving the machine A 9 Insert Crashes with vertical window envelopes Field Option This can be caused by the operator side inner finger lifting and catching the window acetate This can be fixed by removing the inner finger A 10 Envelope crashes at deskew rollers Problem resolved on machine effective from Sept 04 also Read Tech Tip A 26 The flap opener intermittently catches the deskew rollers resulting in an envelope crash This is due to the play in the shaft of the flap opener The opener has now been changed to widen the cut out to 19mm If this problem is occurring replace the opener C7383A issue 2 A 11 Noise from loose pins There have been some cases where the clutch pins have been protruding and rubbing against the clutch brake which result in a noi
8. Minor cosmetic improvements 12 02 07 Page 1 57 Technical Tips INSERT HEAD Module lt e lt e N Page 1 58 Technical Tips INSERT HEAD Module A 42 Saving Jobs and Machine Settings There is a risk of losing all these settings during a firmware download For general guidance it is advised to stream whenever possible and especially when the first 2 digits of the firmware level are up issued e g 3 1 x x to 3 2 x x NOTE Although it is mentioned to stream settings problems have been experienced therefore it is suggested to record all your settings and jobs manually Manual trace of machine and Job settings NOTE Adjust address is not traced Connect to head using Am4go Select the job you want to record and go to the run window on the GUI Send and wait for information to be traced Click the OFF button above trace window and copy relevant trace to a text document of your choice Now click the ON button above trace window and repeat for other jobs of interest 23 traces all machine settings and all jobs This is available on V3 2 0 5str and available from V4 0 0 6 and V3 4 0 6 onwards The steps required for streaming are as follows 1 Open am4go exe 2 0 0 17 or later diagnostic tool Ref below and plug debug box into head serial link J14 check machine is communicating as normal 2 Download V1 0 2 40 to head unit only 3 Click Jobs Settings to bring up Stream Jobs and Settings b
9. Peers ey pF Enger Heb Tz enm sj Click on the start button to start saving what appears in the trace screen Click on the stop button to stop Click ON button to log trace 12 02 07 Page 1 54 Technical Tips INSERT HEAD Module 12 02 07 Page 1 55 Technical Tips INSERT HEAD Module Page 1 56 Technical Tips INSERT HEAD Module Autoending Previously if the machine had autoended with an empty prime hopper and the machine had timed out It was impossible to get the PC to understand the machine was empty and the only way around was to run one more group and hen press autoend while the machine was running Now you can press autoend button to complete the job run and mark reading sequences when the machine empty and in the ready state Document ID implemented Available for all barcode reading hoppers Datacard ONLY Current Languages support by PC English German French Spanish Flemish Dutch and Croatian 2 8 Envelope Feed Mode Only This has been introduced to help with machine set up Maxi Plus on run screen GUI Supervisor menu 2 9 OMR Features OMR reading feeder available Global matching available on Plus only 2 10 Improvements to Insertion Envelope settling times and Finger activation optimised for greater reliability Envelope Deskew times increased Dual envelope loading
10. Am4Feeder V3 4 x x am4 Am4Feeder V3 4 x Am4Feeder_V4 0 x x am4 Feeder x am4 Card Folder Mk1 Am4Feeder V3 4 x x am4 Am4Feeder V4 0 x x am4 Card Folder MK2 Am4Feeder_V3 4 x x am4 Am4Feeder_V4 0 x x am4 2 Plate Folder Am4Feeder_V3 4 x x am4 Am4Feeder_V3 4 x Am4Feeder_V4 0 x x am4 x am4 3 Plate Folder Am4Tpf Ilssue2 V3 4 x Am4Tpf Issue2 V3 4 x Am4Tpf Issue2 V4 0 x single and 3 bin x am4 x am4 x am4 Am4go Application Am4Go_V2 0 0 17 PFETraceTool V3 0 0 6 Latest GUI B3 x x x 4 Simulator Now called PFE Trace tool and can be found on the PFE Technical Web Page Head Unit IMOS PC Software 12 02 07 Page 1 53 Pre Dongle Head CPU Earlier than Issue 7 Dongle Head CPU Issue 7 or later MaxiMailer PC version Firmware Am4PlusPC_V4 0 x x am4 Installation File Rev_ 2 0 1 0 Upgrade file V2 0 1 0 Am4Feeder_V4 0 x x am4 Am4Feeder_V4 0 x x am4 Am4Feeder_V4 0 x x am4 Am4Tpf_Issue2_V4 0 x x am4 Technical Tips INSERT HEAD Module Latest Version of Am4go is V2 0 0 17 this version is easier to capture the trace With the latest version of Am4go V2 0 0 17 onwards it is advised to capture a trace using the Start Log and Stop Log feature This will automatically save the trace in Traces folder within this application for e g if the amg4o is located the drive then trace will be stored within SoftwarevAm4go Traces
11. If fiting Deep Throat Centre Fingers attach plastic extension strip to underside of Envelope Deflector Plate on Envelope Feeder Assembly e Replace Envelope Feeder Assembly ensure that it is seated correctly into the main chassis and covers 12 02 07 Page 1 13 Technical Tips INSERT HEAD Module A 7 Wetter Guide for insertion area Field Option A Wetter Guide B7941A can be fitted to the Sealer Cover assembly when clearance between pack length and envelope depth is outside specification 6mm min which can cause insertion problems Early units will require the addition of 2 fixing holes to fit the part Drill Plate D114 326A can be used as a drilling guide Filed envelopes can ride up over the wetter beam if the insert pawls are set to push the pack right into the bottom of the envelope The cause is that the envelope flap is still gripped when the pack hits the bottom of the envelope causing the envelope to pivot upwards and flip over the top of the wetter beam This can be mistakenly diagnosed as a miss insertion caused by non entry of fingers For some out of specification applications for example a thick pack into an envelope with insufficient clearance the fitting of a Wetter Guide can resolve the problem Some Canadian applications may be particularly vulnerable to the problem as Canadian 9 envelopes are 4 deep giving less than 3mm clearance when inserted into a 10 envelope 4 1 8 deep This field fix shoul
12. Rubber Roller Restorer E0483A A new cleaning agent is available for cleaning ALL rollers on the MaxiMailer and MaxiMailer Plus This is water based cleaner which is aggressive enough to remove toner from the rollers 12 02 07 Page 1 50 Technical Tips INSERT HEAD Module A 41 Updates to MaxiMailer Software Firmware versions and introduction of MaxiMailer Special Edition ref TT A 41A for Jan 2007 Updates Also refer to TB1420 104 for additional actions There are Hardware and Firmware Compatibility issues associated with the introduction of the MaxiMailer Special Edition A security devise dongle is fitted to all Insert Heads to distinguish from other products in the MaxiMailer range The dongolising of the MaxiMailer requires a new version of firmware this will be version 4 It also requires a new issue of the CPU PCB in the Insert Head this will be Issue 7 or later There are backward and forward compatibility issues that will complicate some processes e g the ordering of CPU PCBs as spares The compatibility rules are 1 Version 3 firmware will not work on an Insert Head CPU PCB of issue 7 or later 2 Version 4 firmware will not work without a security dongle 3 An Issue 7 or later Insert Head PCB will not work without a security dongle If a replacement issue 7 or later CPU PCB is required it must be returned complete with its dongle If a replacement CPU earlier than issue 7 is required it must be r
13. x x gt Lj Memory storage capacity for applications 20 ee Eo Unlimited memory storage capacity applications Poe k kx x x x sq Database for stationery and applications x x x x k Y Y Restricted zer anness rm sistem with PIRIInazzwunrd nrntertinn Technical Tips INSERT HEAD Module Statistics Capabilit Event laa Event ig Ex ok x x xk xk x x k Document counts from each hopper kx k k x x x k Poe xk x x x n x x x Dutputlad x Fostal manifest Cycling 5 Sheet from each hopper collated on the Fy on 3 plate tolder 3750 350 4100 i sheet fromm top hopper insert pack 3750 3750 3750 3750 3750 arso 3750 400 _ Psheetsfromonehopperviaaceumulator ifited 13000 000 3000 2000 2000 4000 4000 chests from one hopper via accumulator 12009 120001 2000 2000 2000 2650 Ethernet connectivit View statistical information remotely x x x x x x x x vx 1 L 1 1 1 L L L LL Remote diagnostics ower internet uzing
14. E El El gE El El ve v Divert blank Form between groups E M Reverse Readingi El El m E E E E j v ESER ES ES ERE Form Sequencing E E E E a Eb v pape taf at Flexible Form Sequencing start at ar 1 Pulse conveyor mark if conveyor Fitted E gk mH Ek a m x v eee Halt mark Hm z g Em a x v pape taf t Farit lgnore Blank m m m m gm m m j v a Standardpitches m m g g gE gm v j TIE 8 0 2 x x x J x x x vc v Pepe E BIS x x c E in Match Group Securit MMatchingbetweenfeedmodules x x x x x x x Custom pitch option x x x x x x x x F Barcode Heading Featurez PFEBSCCode3of8 E E m g m gm a e j v End of Group Mode group mark onlastpagefed El m m m g amp gj sv fa ew x x First of Group Mode group mark onfirstpagered x m amp E E gm m v Pa x j x x CustomerlDgroupingonl x E s E E a m j e j ve Selectiee Feeding E El E El El El gm s v x Diver
15. Figure 10 Finger not returning inta home position Check during running if the finger arm fails ta return home Check both sides Figure 11 Finger return spring tension Increase the spring tension both side s Figure 12 Insertion crashes due to fingers digging into envelope Finger dig into envelope 12 02 07 Page 1 36 Technical Tips INSERT HEAD Module A 19 Belts jumping on Head Upper clam assembly 7041 Problem resolved on machine effective from Jan 05 Clean ALL pulleys and idlers to remove the toner that has deposited onto the teeth form do not use grease If problem persists replace ALL Aluminium 25T pulleys with Plastic 25T F1375A pulleys A 20 Envelope Jam at Guide Bar C9436A see A 20A for 2007 updates If there are instances of the envelope getting caught as shown below then the following corrective actions can be attempted i Check by removing Collate Roof Cover B7502F that all Rollers on the Envelope Feeder Assy A7061A are aligned against all rollers on the Collate Pocket Clam Assy A7060A If misaligned this can cause envelope skew and insertion problems ii Envelope Shim on Flap Grip Roller Assembly A7072A can be lifted up to guide the envelope into the nip of lower rollers as per a Note on some machines this shim has been fitted incorrectly preventing the shim to be lifted up If this is applicable then remove and fit correctl
16. Jan 2007 mter Relevant Application Qty Description Number Number Assembly required Number B7941A Wetter 42 Head ref To reduce insertion crashes where the clearance Guide e 5 section A 7 between depth of envelope and depth of insert pack gt a is small 287 Wide See tech tip note A 12 for details These are fitted to collate pocket and fingers reduce insertion crashes when running a mixture of wide and narrow inserts 12 02 07 8 Page 1 8 Technical Tips INSERT HEAD Module A 1 Motor Drive Belts and Pulley jumping and making noise Problem resolved on machine effective from June 05 On machines pre June 05 the Main Motor STS Belt F5112A jumped on the pulley amp idler assemblies causing a bumping noise from this area during running If this problem occurs on machines pre June 05 then the immediate field fix is to ensure the idler bridge B7420A shear buttons are located as illustrated below Also a very light smear of grease can be applied on the toothed side of the belt that will help until the belt settles in For a permanent fix it is recommended a new Primary Drive assembly A7068A 220V or A7069A 110 be fitted with all modifications Also on machines pre June 05 there have been instances where the motor pulley F1372A 220v and F1373A 110v became loose resulting in loss of drive and motor stalls The corrective actions for this problem is to retrofit a double grub screw pull
17. be done running paper C Now stop the trace by clicking the OFF button in am4go at the top right of the trace window and look for the following PS mm s Slowest 1060 Fastest 1100 d This is the paper speed and the slowest should not be below 1040 mm s If it is then assuming nothing binding mechanically the slotted disk should be changed part number 180 794 Note The motors can be run up in GUI engineer mode best done using Am4go to minimise additional trace information If done this way the current speed is traced as follows opeed 1060mmy ys instead of the above Again this should not fall below 1040mm s Testing of the head is not conducted in this way the envelope stop position variability should a good indication 2mm approx There has been some confusion on the part numbers of the slotted disk sensors The table below lists all the ones used in various locations Slotted Sensor Ref section OLD Part PCB New Number New Location Moaule fi Manual Number Colour applicable PCB Colour Main Clock Disk Insert Head 4a 1 S7 180 746 RED Side Guide Disk 4 1 516 180 689 GREEN Side Guide datum 4 1 515 180 689 GREEN FingerDisk 4 3 19 180 680 GREEN 1 0 Finger Datum 4a 3 S21 180 689 GREEN 180 776 BLUE Fingers Out 4a 3 S20 180 689 GREEN 180 776 BLUE Wetter Home 4a 1 S6 180 689 GREEN 180 77
18. bent downward 35mm from one edge Fits using double sided tape to the middle section of collate pocket roof as shown Technical Tips INSERT HEAD Module A3287A Kit wide collate pocket and fingers A 12A Wide finger kit A3287A Jan 2007 Updates This new finger profile has been introduced to improve the envelope insertion caused by skewed envelopes from pick up These fingers B9324A and B9325A are shorter with a slight downturn at the tip This also enables inserts unto 40mm narrower than the prime document to be inserted without the need to sandwich in between other inserts Support of packs before insertion Problem resolved on machine effective from Sept 05 tape is now fitted standard For greater control spring steel can be fitted in cases of tight clearances on internal side seam envelopes There have been instances where added support of collated documents is required in the Head unit collate pocket before inserting into the envelope as shown below S 12 02 07 Technical Tips INSERT HEAD Module M Tape is now fitted standard to all machines A 13 Envelope Opener Stop breaking C4360A Problem resolved on machine effective from Sept 04 There have been instances where the above have broken from the score line groove If this is the case please replace part with C4360A issue 2 A 14 Operating handles becoming loose Problem resolved on machine eff
19. feature removed Single envelope loading times has been improved The increased delays at speed zero allow enough time to observe the envelope position and finger entry before the documents are inserted This is very useful when trying to analyse any problem areas 2 11 Barcode Reading Max barcode label length increased to 25 Barcode reading feeder available Global matching available on Plus 2 12 CardFolder module Barcode reading and multiples now available on the CardFolder Fold consistency and detent positioning consistency improved with change of two clutches Throughput increased to 2000 hr Now user is correctly prompted to remove packs from output rollers Resolved problem autoending correctly when feeding multiples from CardFolder Calibration cycle works at correct speed when feeding multiples Improved error handling and recovery 2 13 Special Edition MaxiMailer New SE dongle type introduced one module 3 plate folder configuration 2 14 What you get with a 123 804 Extended Features Dongle not available on SE machines Local matching FOG or EOG 3PF top hopper to mid hopper Reverse group sequencing and start count control Extended OMR pitches 1 10 3 8mm 4mm 5 3mm Invisible gate mark i e a single EOG mark only Demand Feed FOG and Barcode on last page fed only 2 15 PFE Trace Tool V3 0 0 6 formerly called AM4go Name changed to PFE Trace Tool because it now supports the Mailer 5
20. is a silver credit card sized label showing product code serial number and as from V3 1 x x the software version also If a module of an earlier software version is fitted it must be upgraded With the release of version 4 all machines now have a security dongle firmware lock added to the CPU PCB However for machines in field without a dongle a new firmware version 3 4 has been released This has the same functions and features as version 4 but operates with no dongle Therefore please note that modules running V3 4 x x firmware are NOT compatible with modules running V4 0 x x and vice versa This applies to insert head feeders folders and CardFolder A 35 F1375A 25T pulleys 25T XL pulley F1375A is used in four different assemblies on the MaxiMailer These have previously been made of aluminium which is now being phased out to be replaced by moulded acetyl pulleys If pulleys are ordered now moulded acetyl items will be supplied which can be used as a direct replacement Any existing spares stock of aluminium pulleys can also be used Machines recently supplied will be fitted with moulded acetyl pulleys The four assemblies where the pulley is used are Overguide Assembly A7117A Lower Conveyor Assembly A7036A Upper Conveyor Assembly A7035A Head Upper Clam Assembly A7041A 12 02 07 Page 1 48 Technical Tips INSERT HEAD Module A 36 Flap catches on the Envelope Opener Field Option see A36A for 2007 update
21. module Page 1 76 Technical Tips INSERT HEAD Module Ribbons are now available separately 182 550 Maxi Head Ribbon Set Now also available in the separate parts shown below 182 550A RIBBON 182 550 PART A 182 550B RIBBON 182 550 PART B 182 550C RIBBON 182 550 PART C 182 550D RIBBON 182 550 PART D 182 550E RIBBON 182 550 PART E 182 550F RIBBON 182 550 PART F 182 550G RIBBON 182 550 PART G 182 550H RIBBON 182 550 PART H 182 5501 RIBBON 182 550 PART I 12 02 07 Page 1 77
22. of Cyanoacrylate glue on the sensor holder 12 02 07 Page 1 44 Technical Tips INSERT HEAD Module A 28 version 3 Excessive Current If this is displayed on the GUI at switch ON this means there is a potential short on the applicable module Plug am4go diagnostic tool into the applicable module and switch ON machine to display the following as shown below example trace from Head module Any failures indicate potential areas in the machine that may require investigation In the case below all have passed and no problem exists ere mcLAET jo ete iN Cent TAC At ion cIEneFickup 01 114 1T Po lEnebriwe 0 114 107 01 114 112 D 14 iti 1 114 1113 0 114 iU 1 4 iti Paseed Hj 144 iti 1 144 1137 0 324 222 Ej 0 114 i07 Passed Le 0 254 25 Passed Ml Look here for 0 114 107 Passed 0 144 141 Pass Fail Dith iti Passed Po iti 0 524 515 0 534 58 0 534 619 Diti 141 Pasas 0 114 i07 Passed ol 12 02 07 Page 1 45 Technical Tips INSERT HEAD Module A 29 Power Supply 26V low error 1054 on version 3 on upwards When Upgrading to Version 3 Firmware there is a potential for the above error to occur Version 3 of the firmware performs an anal
23. returning cleanly after insertion then the following areas should be checked Clutch Pin G0079A This pin can work loose if fitted incorrectly and introduce skew in the solenoid plunger causing the plunger to bind By pushing the pin home fully and fitting a small cable tie across the two pin legs it stops the pin from moving outwards Finger bar Fouling on top hat sensor Problem resolved on machines effective from July 05 also Read Tech Tip A 26 Check that the wide top hat sensor part number 180 776 is fitted and the flag is centralised in top hat as it returns to rest position Note this sensor is not compatible expect with the wetter home for use in other areas Wider Top Hat Sensor 180 776 12 02 07 Page 1 12 Technical Tips INSERT HEAD Module A 6 Special Fingers for Insertion Problems Field Option There are 2 special versions of insertion fingers Deep Throat Centre Fingers and High Window Fingers Refer to the Finger Replacement Instructions below for the best fitting practice Deep Throat Fingers see tech tip note A 18A sub note 10 High Window Fingers These may be required for some specific US envelopes The High Window fingers are used in place of the standard outer fingers They are 5mm longer and are fitted with the tip high points inboard These fingers are specifically designed for envelopes with windows positioned very close to the flap crease and outer edge For this app
24. rubber feed tyre is now available for the envelope or feeders 16 Easy adjust separator assembly A7353A Field Optional Only see TT note E 5 b for details Datacard machines ONLY 17 Dell PC casing to the protect PC in the stand and small size keyboard with mouse to be introduced 18 MaxiMailer Specification Change The wide outer fingers will be fitted as standard This means standard machines can only insert into envelopes with a minimum width of 7 If customers need to use narrower envelopes typically C6 size then the machine will need to be fitted with Narrow Envelope Finger Kit A3348A 19 Current MaxiMailer Features and Product Guides available on request see extracts below 12 02 07 Page 1 70 Technical Tips INSERT HEAD Module MaxiMailer Product Features Guide Issue 21 Dec 2006 Hardware Software and Firmware Features and Options 1430 Head Future Mat Standard EN Optional ox Mat Available Option Applicable 145044 Std Feeder 144244 Ibin SPF 2 Plate 3 Plate Folder Folder 143048 Head 1450 Std Feeder 1440 2 Key Mazimailer Special Edition SE roduct Code Tables on page 2 14047 1430 head M52AA Tower 1430AB Head Feeder 1450AA Std Feeder 1440 2PF 1443AA 3PF 1402BA comprises 1430 Head 1450 Tower Features Feeder Pe we ew ew
25. tight can check this If so then remove both sides and bend until correct as shown below PICTURE After fitting run a handful of envelopes up and down the hopper to set the side guides and then lock them in position ensuring they are not too tight along of the hopper guides In addition ensure the side guides do not rock side ways and across the length If so it may require packing with Mylar from underneath oide guide ii Check and set the separator gap correctly as the manual This should be lighter with standard pick up roller types and slightly heavier with the Pre feed assembly ili To assist feeding Mylar tapes can be fitted onto the side guide as shown below and also onto the returns and overguide Tapes on envelope feed sideguide returns Mylar on the envelope feed side guides Tapes on envelope feed overguide 12 02 07 Page 1 25 Technical Tips INSERT HEAD Module iv Check envelope pick up Jogglers are aligned if misaligned can be glued in position v Check the envelope pinch rollers are turning freely otherwise this can skew the envelope vi Check and implement Tech tip note A 20 Check that the envelope pinch rollers are turning freely otherwise this can skew the envelope k Stiff chain and pawls not fitted correctly If experiencing sporadic insert crashes check insert pawls are aligned with each other and that there is no resistance when manually mov
26. 201A is available and can be fitted to protect the splitter board below the wetter tank from wetter fluid standard on new machines effective Sept 05 i Collate Pocket Issues may need to be incorporated see tech tip A 12 j Finger Wear issues If there are instances of the current plastic outer fingers becoming worn from the tips new metal fingers B9203A and B9202A can be fitted if required Now fitted standard NOTE fit tape onto envelope feed bridge B7496A to prevent catching on cut outs as shown below In addition check and ensure that the finger brackets both operator and drive side are not bent up as shown below If so this MUST be straightened 12 02 07 Page 1 23 Technical Tips INSERT HEAD Module Mylar fitted to prevent fingers catching on cut outs 2 posn G6210A and G6211A see below Tape 17 18mm wide to fit into cutout and extended to envelope bridge profile Check that brackets both operator and drive side are not bent up If so this MUST be straightened 12 02 07 Page 1 24 Technical Tips INSERT HEAD Module j Envelope Skewing check Check side guides are set correctly this is critical If the envelope seems to struggle to pickup and feed this will have a tendency to skew the envelope and result in an insertion crash corrective actions are i ensure side guides are not over bent Run an envelope perpendicular to the guides without the envelope going
27. 6 BLUE Separator Adjust 1 Feeder 4b 1 S14 180 689 GREEN Separator Adjust 2 4b 1 S15 180 689 GREEN Y Main Motor Disk Fold Plate 2 Disk Fold Plate 3 Disk Main Motor Disk 4 1 S7 180 692 GREEN 4c 1 S9 180 692 GREEN 4c 1 1 180 689 GREEN 180 794 YELLOW Note the wide slotted sensors part number 180 776 is now driven harder in software to ensure correct set up d 250 E Fold Plate 1 Disk 4 1 58 180 692 GREEN a SS p 12 02 07 Page 1 43 Technical Tips INSERT HEAD Module A 27 Envelope Deskew Sensor Errors Also Read Tech Tip A 25 and A 51 sub note 1 This sensor is susceptible to capturing dust and movement which results in error 107 clean envelope deskew sensor At first instance advise customer on how to clean by removing the envelope pick up rollers and then using PFE approved air duster blow out both parts of the sensor In some instances we have found there is too much movement within the sensor holder if this is the case it is advised to place one drop of Cyanoacrylate glue on the sensor holder as shown below Once aligned re calibrate sensor and check by running envelopes for above error new sensor bridge B1797A issue 4 has now been modified to prevent the sensor from moving within the holder and can be fitted if required optional Remove rollers to expose sensors for cleaning One drop
28. ERT HEAD Module A 43 Envelope flap catches on the Sealer Ski B7464A when running in No Seal Mode Field Option If there is a requirement to run the machine in NO Seal Mode and closing flaps there is a potential with certain envelope flaps to catch on the sealer ski If this occurs a no seal bracket B9120A can be clicked into place to provide support of the envelope flap as and when required Note that this part can only be fitted with the latest version of the sealer ski B7464A issue 2 or later Parts required 1x B9120A No seal bracket 1x B7464A Sealer Ski latest version 4x P2278A Pusher Pivot 4x E2771A M3x8 Cap Hd St Steel 0 07m x E0422A Vinyl Tape No seal bracket that can click into place 12 02 07 Page 1 61 Technical Tips INSERT HEAD Module A 44 Envelope crashing at Reversing Closing If this occurs carry out the following actions Observe and run machine at slower speeds with the head side cover linked out Check that the reverse position allows the envelope to tilt upwards and position itself neatly into the nip of the seal rollers near to the seal plate as shown below SEALER ROLLERS SEAL PLATE WETTER OUTPUT ROLLERS werrer tank 7 ER SKI gt DGE CHASSIS BR A
29. ING FINGER 214 x 2 G1196A x 2 __ 3 5mm E CLIP E5055Ax2 MIDDLE FINGER SUPPORT BISTIA x 2 Ps FINGER EXTENSION XL DR 9321 FINGER EXTENSION XL OP 2 B9322A GF NYLOC NUT E355 A x 2 be found on the PFE web page see below for extracts 12 02 07 Page 1 31 12 02 07 Technical Tips INSERT HEAD Module Envelope Feeding Set up O ions Alesse nae that any combi ration of these tips could help with particular envelope types en Envelope type settings Fick upteed system required sett r1 Separator Sonmg Action Envelope lead edge cuned wisted and Clearance up does sit parallel to the Separatonbickup roller resulting in skewed feding see figure 1 Tractor but espenencing streaming and doubles issue Setup as point 2 but still experiencing steaming and doubles issue Envelope iz Sitting fat in the hooper and Clearance up does hawe any eur across the lead As above but experiencing pick up issue Fr above and pick up issues persist Running cudedtwisted envelopes longer haring stream or double issues but only experiencing skew Additional Mates for qood erma ope feedng fed tractor part v72 17 Separator pad 0 5mm Remove outer upper tyres fom he pre f amp ed assembly Separator pad 20 5mm envel
30. ION FOR PFE MAXIMAILER PLUS 1 2 1 In folder PFE MAXIMAILERPLUSYREV 1 1 0 4 click SETUP EXE 1 2 2 Follow instruction and install the drivers 2 INSTALLATION ON MAXIMAILER PLUS MACHINE PC CAN CARD DRIVER INSTALLATION 1 In folder IXXAT082005 double click CDSTART EXE 2 Click ENGLISH or DEUTSCH 3 Click Driver Installation 4 Click VCI Version 2 16 for Windows 9x Me 2000 XP Service Pack 2 5 Follow the instructions and install the drivers ei lI lI 2 2 2 2 2 2 2 2 HARDWARE INSTALLATION 2 2 2 f you have a PCI Card 179 736 follow the instruction in the manual and install the card in the PC 2 2 1 If you have a USB to CAN 179 780 179 781 connector Compact connect it to a USB port on the PC always use the same USB port in future Double click on file USB CAN REG in the PFE MAXIMAILERPLUS folder 2 3 MAGO INSTALLATION FOR PFE MAXIMAILER PLUS 2 3 1 In folder PFE MAXIMAILERPLUSYREV 1 1 0 4 click SETUP EXE 2 3 2 Follow instruction and install the drivers 12 02 07 Page 1 64 Technical Tips INSERT HEAD Module NEW CLUTCH AND CLUTCH PLATE A7366A FIT SHIMS G6028A amp OR G6168A QTY TO SUIT A CLUTCH GAP SETTING OF 0 15mm 12 02 07 Page 1 65 Technical Tips INSERT HEAD Module 12 02 07 Page 1 66 Technical Tips INSERT HEAD Module 12 02 07 Page 1 67 Technical Tips INSERT HEAD Module ENVELOPE SENSOR BRACKET PE
31. NT UPWARDS 2 THAT IT RESTS ON TOP OF EHVELUPE IT 15 THE INSERTION ARES EMVELDOPE INSERTION IMTEFPhISL FINGERS SHOWA Ih THEIR CONDITIOM SET WITH 4mm SOLED STROKE ENVELOPE DEFLECTOR R21754 ENS BENT AS SHOWM HOLD UF THE TOP FACE DF THE GUIDE TAPE GEZ 144 BLUE COLCUR FITTED TO CENTRE ENVELOPE FEED EF 03 1 1 m H a EX gems E mm Eee mam E FT ENVELOPE DEFLEGTOR R21754 12 02 07 Page 1 68 Technical Tips INSERT HEAD Module OVERGUIDE o ENVELOPE INSERTION DIRECTION XTERNAL FINGERS SHOWN IN THEIR PULLED IN CONDITION SET WITH 4mm SOLENOID STROKE 12 02 07 Page 1 69 Technical Tips INSERT HEAD Module A 56 Miscellaneous Jan 2007 improvements 1 Punched arrow indicators added to identify sensors 2 Short Overguides B7833A at collate pocket entry replaced by Central Overguide B9313A to improve delivery of form trailing edge into pocket 3 Improved location of latch springs in the collate pocket clam side plates 4 Input Conveyor shaft removal of grooves to improve fatigue strength 5 Output Sensor Bkt B7488A has improved retention of reflective sensor 6 PC Lead change to angled connecto
32. T BODY D 53384 FIER NUT SPARKS FINGER MIDOLE FINGER EXTENSION DRIVES a 375384 NOTES 1 amp 3 EPRIBNG FINGER MIDOX E FINGER SLIPPCRT BB8311A 2 MIDDLE FINGER EXT OPERATOR BTBAT HOTES Z E 3 sm oc E35STA MOITE 2 FINGER prm E CLIP PAA EPISKA SPRAG ANGER 11364 1 FINGER OPERATOR E Bas 34 E CLIP Sr Fares ELS ESSA pg t jae br aa Wp NOTES i PART OF SPARES ASSAY 1 PART OF SPARES NOTES i PART CF SOARES i PART OF SOARES ATTA 12 02 07 Technical Tips INSERT HEAD Module CLUTCH PIN x Emm CSK HD SCREW SIOTSA E277 1 MM M2 5 x 12mm FIN GROOVED SPRING LINK FINGER SOLENOID 2 E5D82A GIRI 181 142 GEAR 45T x Emm FINGER ARM DRIVES ASSY ESITA F4175A OUT SENSOR 54331A a 5 Ps RIVET 3 5mm a 160 145 iB Lem 1 3 Po E Pad el PCB RIBBON SPLITTER 7 M4 WASHER AM 80760 401 1A E4011A E M4 x amp mm CAP HD SCREW 7 E2512A FINGER STOPDRIVES er REZIA Y VINYL i 2 i WIRED MOTOR 175 602 204 ec HEAT SPRING SOLENOID G1122A FINGER ROD FINGER ARM 77 7 HA CITEA GEAR 35T x Emm
33. Technical Tips INSERT HEAD Module MaxiMailer Service Engineers Technical Tips Documentation Jan 2007 The following documentation describes all MaxiMailer field issues and corrective actions Please refer to these documents before any service or maintenance is conducted Items highlighted thus are Jan 2007 additions INSERT HEAD Module 1430 1431 and variants Technical Page Main Area INSERT HEAD Date Date Technical Mandatory Tip Number 1430 1431 and variants Effective Effective to Bulletins Number from if applicable noise Loose Pins on Pawl Chain sprocket causing loss of Oct 03 ELLEN drive A 3 1 11 Misaligned insert Kicker Pawls causing insertion Oct 03 Jan 06 v crashes A 4 1 12 Polycord Belt stretching causing motor stalls Error Oct 03 July 04 Codes 8 amp 32 112 _ Insert Fingers fouling causing insert crashes Oct 03 Sept05 VY throat 223mm OPTIONS EARS REIN crashes OPTIONS Wetter Leaks Oct 03 May 04 TB1420 101 BN 500000070 12 02 07 1 1 1 Technical Tips INSERT HEAD Module MaxiMailer Service Engineers Technical Tips Documentation Jan 2007 INSERT HEAD Module 1430 1431 and variants Technical Page Main Area INSERT HEAD Date Date Technical Mandatory Tip Number 1430 1431 and variants Effective Effective to Bulletins from if applicable Cashing of inserts with vertical windo
34. and drive EM Insert feeder E outer wheels C8194A A 267A Slotted This feed wheel has advantages when feeding Feed Tyre 5 amp Feeder inserts with a powdery finish Insert feeder D0037A A 268A Silicon Envelope These provide added grip on certain glossy Feed Tyre Feeder stationery C8193A 7269 Roller HI Envelope These provide high grip on certain glossy stationery GRIP Feeder EPDM l Insert feeder Insert feeder 12 02 07 6 Page 1 6 Technical Tips INSERT HEAD Module MaxiMailer Service Engineers Technical Tips Documentation Jan 2007 Part Relevant Application Qty Description Number Assembly required Number D0059A A7271A Coated Envelope 6 off These provide high grip on certain glossy stationery Silicon Feeder Feed Insert feeder Wheel AT217A AT217A Pre feed Envelope 1 off This assembly can be fitted to improve the pickup of 18645 T cover See Deep amm See Tech Tip Note A 18 sub note 10 for details description Throat n for details Centre Fingers Assembly Feeder propeller cut envelopes Note B1864S cover must be fitted with this assembly oee See tech Tip Note A 6 for details High Window Fingers description for details 12 02 07 1 7 Technical Tips INSERT HEAD Module MaxiMailer Service Engineers Technical Tips Documentation
35. ast required Erue pp Pog ithe hat HIE wr ERI he Notch ual re moues tie towards the clozeraad 4e back gee 7 pickap Estes fee edlig Se tip polits 2 3 zkew fee Reding Se tp polit 1and 4 skew at l z The check rte Ogee whetherthe envelope creage Pale tie on eltherside The skew limits are with l tie ztartead polit ofthe fee Tj expe rE Clq skew beyond t E tie a check polit 1 2 T brary catch polis ti DI ql the path Figer ach ato ztartpos Ito s Mak the He ofthe creare Ire aad tex Bed ab e elope kaid O fe ztartortke woth postion Thea El the bak ok ie bpe Feder ske plates check tie The ret poets os E ziii qosrarzikktiks Deb kd tie marked Gazelle zee Ngee 9 mti kot zet tie med din Dp on Oi FOR ea rare dm stoke E etok tie The tok poke ithe r zii Site am bg the kas steam Ted heb fiere E a tebe boy or he e tie Tiger aid Brats oue gide bat accarred carem Iw Emoue the Med aid check polit 23 d T Fingers wot rete l lito kome ThE BUENA Check macklie ret to kome El zee QI E 10 Core cte ac
36. cket entry and input conveyor either using am4go or using the engineer function in the GUI Then check ribbon cables and splitter boards associated with the above sensors There have been some instances where the pawls catching on the ribbon cable can cause this problem check this by removing the pocket backstop Assembly A7058A pg 4a 23 Service Manual A 39 Plug and Play This is a new feature with the latest firmware at power up the machine checks for the number of modules fitted type and calibration information This is the detected machine configuration The detected machine configuration is then compared with the programmed machine configuration If there is a miss match the user is given the option to accept the detected configuration accept the current programmed configuration or go to the engineer setup screen and edit the current configuration The key benefits of Plug and Play are if a module is added removed or changed to a different type the new configuration will be detected and can be readily updated if a board is changed on the head or module the new board will be detected and settings can be readily restored from the INI file if a new PC is fitted the configuration can be read from the machine IMPORTANT DIP switches must be correctly set to the module address on power up If new CPU board fitted on GUI Head then accept settings If new CPU board fitted on GUI Module then edit and configure A 40
37. d only be used when it is evident that adjusting the Insert in Envelope Position in the GUI advanced menu cannot solve the problem This is because using the insertion pawls to cram insert packs into an envelope will put additional loads onto the machine mechanisms and may result in premature failure of some components A 8 Wetter Leaks Implement TB1420 101 Tech Tip A 15 A 17and A 17A The following are notes from the TB There have been some occurrences of fluid leaks in the wetter system as follows 1 Leak from the drainpipe connector on Wetter Reservoir B7480A Early units had a potential problem where the O ring seal did not seat correctly and was susceptible to damage on assembly The connector and its nut have been re designed to prevent this If leaking is being experienced here replace with the following parts Pipe Connector P2216A issue B or later Drain Nut P2217A issue B or later amp O Ring E0169A 2 Leak from the float switch on the Wetter Reservoir The rubber sealing washer for the float switch should be assembled on the inside of the reservoir There has been an instance on an early unit where the rubber washer was assembled incorrectly on the outside of the reservoir 3 Excess wetter fluid carrying through from the wetter tank foam can drip down the rear face of the tank and migrate by capillary action along the Tank Channel to the Overflow Pipe After a period of time drips form at the head of the Overfl
38. eam bounce now eliminated by firmware upgrade V4 0 0 12 or V3 4 0 12 onwards that keeps the Solenoid Up ON for longer 3 Certain types of crashes cause the pawls to jump in firmware version V4 0 0 12 Dongle or V3 4 0 12 Pre dongle onwards the Insert pawls will now only move from the pause position when the wetter is home and the trailing edge of the envelope is seen at the wetter output sensor Note if a M4 lock nut is fitted onto the Sprocket Bracket Assembly A7059A as shown below ensure this is slackened off Lock nut fitted that allows 5mm compression 4 Pawl brake not working or pawl bracket broken refer to Tech tip note A 18 Additional Checks 5 Distorted chain end links causing the chain to ride up on the sprocket 6 Stiff chain links causing the chain to ride up on the sprocket 7 Idler sprockets not free running on either fixed shaft or sprung shaft or both Must remove this assembly and clean during a PM Ref TT note A3A sub note b for further actions 12 02 07 Page 1 11 Technical Tips INSERT HEAD Module A 4 Polycord Belt causing Motor Stalls Error Codes 8 amp 32 Problem resolved on machine effective from July 04 also Read Tech Tip A 26 Intermittent error codes 8 amp 32 which indicate a jam but there is not False Alarm The tension of the Polycord can cause this problem check the belt length is 930 mm Max A 5 Insert Fingers If the Insertion fingers are not
39. echnical Tips INSERT HEAD Module e Check envelope stop posn is correct for the envelope see Photo below The stop posn can be moved forward e g ve takes the envelope towards the wetter area Note that if this is too far back it can restrict the envelope from opening See note d Envelope crease line to be positioned within or advanced of notch in bridge f Fingers are cleanly entering envelope not tearing the edge or getting caught on the window If so the fingers can be moved inwards or special fingers can be fitted see tech tip note A 6 g Check Documents are inserted too far into envelope causing envelope to lift over wetter beam or ii inserted too shallow causing box folding in sealing If so Insert in env pos can be adjusted e g ve pushes the insert into the envelope h Pawls are stopping consistently before reaching the collate pocket and insertion area this can be caused by brake not engaging correctly there have been instances of the stop of the brake bracket breaking which can result in inconsistent pawls stopping If this has occurred then a new brake bracket 8728 Issue 2 must be fitted standard on new machines effective Sept 05 ii pawls digital sensor not working check this in Engineer iii wetter fluid on the splitter board mounted directly under the wetter tank Note this is mainly caused by moving the machine without draining wetter tank PCB Shield G6
40. ective from Sept 04 Also Read tech Tip A 47 There have been instances of some handles in the head feeder and folder becoming loose If this has occurred please apply Red Loctite or use cap head screws A 15 Wetter and Finger Solenoids sticking Problem resolved on machine effective from Jan 05 The Solenoid Plungers are Wearing and therefore preventing full movement of fingers and wetter beam Finger Solenoids part no 181 142 and Wetter Down Solenoids 181 119 Drive Side and 181 142 Operator Side Corrective action Must be replaced with Teflon coated plungers part number ECP1317_30A or complete solenoid A 16 Clutch Pin G0079A falling out or breaking on the EC30 clutches only see A 16A for 2007 updates Problem resolved on machine effective from Sept 05 There have been instances of the standard clutch pin GOO 79A used on the EC30 i e connector type clutches brakes 179 214 breaking or falling out during running The corrective action is to fit the new style clutch pin part number G0167P 12 02 07 Page 1 18 Technical Tips INSERT HEAD Module A 17 Wetter Sensor getting wet resulting in Wetter Jam Errors 36 37 or 38 See A 17A for 2007 updates Problem resolved on machine effective from Sept 04 There have been instances of excess wetter causing problems with the wetter output receiver sensor Ski Bridge e g errors 36 37 or 38 This sensor is now enclosed within the new ski bridge 7464 A
41. ed to check this turn by hand one complete cycle Check that the pawls are manufactured incorrectly if not they could drag on the insert chain see below Manufactured incorrectly This one is too far down causing drag good on chain 12 02 07 Page 1 26 Technical Tips INSERT HEAD Module A Mylar strip part number G6195A can be fitted for particular envelopes with a short flap shoulder this may be required to prevent the insert catching on the edge of flap during insertion Material 0 25mm 0 010 Polyester Shim Stock Mylar Clamped between Aluminium bar T pieces clamped not stuck down 7 8 59 56 _ 12 02 07 1 27 Technical Tips INSERT HEAD Module MICDLE FINGER SUPPORT FINGER EA 1A 11 PIAA FINGER DRIVES x G11354 B OA 1 SPRING y gH 511954 zo o7 MIHYLOCNUT ef DNA E355TA IMOTE 1 35mm E CLIP WT EMESA I i s The E EI E it A ue FE CUP HE 27113 11 L DE TED gt 7 FINGER PIM FINGER AIT LH gt i F454 Lue FINGER BODY T Wm DSA FINGER ALISH T il D OU FINGER BODY QA oot 53384 LR Imm r ESOT Pi R FINGER BODY FINGER BLUSH COA
42. erate CSW rest files which the end user can analyse for basic integrity checking x x x x x x m AFEN n SISA PATS DEE EEE DEE NE 20000 28 22000100202 ETE EEE EEE EEE EEE EE PICS Software Package Integrity checking software package x x x x x x amp m Late divert facili x z x x x x 1 1 1 1 Generate re print File ete ete x x Requires OMA arcade and an accumulator on 3 Plate Folder ra be fitted Except of Group Diverts to either accumulator or collate pocket Requires card Folder module 44464 OMAR definition position on page and document size must be identical the prime and matched document Variable grouping is only possible from one hopper FOG on document iz nat possible When more than 2 OMA heads are fitted an Expansion Kit 14 191 is required 25 184 131 are required For mare than 4 OMIA heads Standard MMasimailer requires extended Features dongle 12 02 07 uut Technical Tips INSERT HEAD Module MaxiMailer Product Code Guide 11th Jan 2007 Issue Hardware Software and Firmware Features and Options MaxiMailer Configurations 1 0 MaxiMailer SE Fixed Configurations hardware non upgradable Fixed confi
43. eturned with the machine details for a replacement issue 7 CPU with dongle The dongle is a separate PCB with a coded EPROM and is mounted just above the CPU On production machines it is secured to the chassis with screws For retrofitting a Dongle Bracket kit A3316A has been created for securing a dongle PCB to an older Maxi head Product Code Structures for SE MaxiMailer 1402AA comprises 1430AB 1450AA 1440AC SE Logo SE 2P Dongle 1403AA comprises 1430AB 1452AA 1440AC SE Logo SE 2P Dongle 1404AA comprises 14 30AB 1420AA 1443AA SE Logo SE 3P Dongle 1405AA comprises 1430AB 1452AA 1443AA SE Logo SE 3P Dongle Notes Any extra feature e g an accumulator for the 1443 will require an additional order to the product codes shown Operating Instructions and Technical manuals will be generic for the Standard MaxiMailer and the MaxiMailer SE PCB s supplied will not be loaded with firmware Dongles will be specific to the machine configuration that is specified by the customer The firmware V4 or later covers all variants of the machine and works in unison with the dongle to adapt to the machine to which it is fitted Spares policy and Pricing 1 Only issue 7 or latest PCB s will be supplied as spares 2 An issue 7 PCB will not work as a direct replacement for any previous issues without the correct dongle required for the machine under repair 3 All parts will be chargeable through the cost of the dongle will be re
44. ews on the stops 4 Slacken the adjustment screws on the down solenoid each side Hold down the wetter beam and slide the solenoids so that the plunger is bottomed when the arm is pulling downwards to take out any play in the pivots Tighten the screws gt With the wetter beam in its raised position slacken the screws on the up solenoid and slide it so that with the plunger bottomed any free play is taken out of the spring without the spring being tensioned Tighten the SCLEWS 6 Replace the side covers The wetter beam is now correctly set Wetter adjustments in Engineer mode It 1s important to note that the wetter beam must be correctly set as described poor to making wetter adjustments in Engineer mode see Settings on page 3 17 for Maximailer or Units Setup on page 3 21 for Maximailer Plus If the beam 1s not correctly set engineer adjustments will not be able to eradicate wetting problems 12 02 07 Page 1 21 Technical Tips INSERT HEAD Module A 18 Insertion Crashes corrective actions required see A 18A for 2007 updates Also Read Tech Tip A 3 A 5 A 6 A 7 A 9 A 12 and A 15 Run machine at speed 1 walk mode with covers linked out to highlight insertion area The following checks and adjustments are required to ensure good insertion of documents a Check that the fingers and collate pocket are setup correctly Ref manual page 3 16 b Check 2mm clearance in the collate pocket with widest in
45. ey F1372A 220v issue 2 or F1373A 110v issue 2 onto the modified Primary Drive assemblies Shear buttons located onto side flanges Additional fixing points on new bridges Double Grub Screw location 12 02 07 Page 1 9 Technical Tips INSERT HEAD Module A 2 Loose Pins on Pawl Chain Sprocket Problem resolved on machine effective from June 04 Grooved pins 5078 can fall out on 15T Pawl Chain Sprocket F30444 These pins should be an interference fit If not it is suggested that the sprocket and pins are changed For a field fix Cyanoacrylate adhesive Loctite 603 Green can be used to secure the pins in place Please Note that the pins should be fitted into the sprocket first then the aluminium hub pushed on after Grooved Pins E5078A fitted on 15T sprocket Aluminium hub pushed on after Use loctite to secure the pins in place 12 02 07 Page 1 10 Technical Tips INSERT HEAD Module A 3 Misaligned Kicker Pawls See A 3A for 2007 updates Problem resolved on machine effective from Jan 06 Insert Kicker Pawls B1818A are misaligned and cause a jam in the insertion area The contributory factors and corrective actions are 1 Pawl link can lift above the centre panel B7468A page 4A 2 item 26 on one side only causing the pawl chain to jam and jump This has now been fixed by reforming the centre panel If you find this problem order a new centre panel 2 Wetter b
46. funded using the RMA system when the old PCB has been received by PFE UK 12 02 07 Page 1 51 Technical Tips INSERT HEAD Module Switching the machine off and on For V4 if for any reason the machine is switched off and then on again e g to clear an error the machine must be left for at least 5 seconds after switching off before switching back on If not the error message Security device missing will be displayed Dongle Board part numbers and fitting 123 800 for standard MaxiMailer 123 801 for MaxiMailer SE with 2 Plate Folder end module 123 802 for MaxiMailer SE with 3 Plate Folder end module 123 803 for MaxiMailer with extended special features To re fit a Dongle board to an existing machine pre Oct 05 a dongle bracket kit is required A3316A This contains 182 745 loom Maxi dongle link E0033A double sided tape E0349Ax2 spacers and R6053A dongle bracket 12 02 07 Page 1 52 Technical Tips INSERT HEAD Module dates to MaxiMailer Software and Firmware versions continued see TT Note A 41A for Jan 2007 Updates MaxiMailer GUI version MaxiMailer PC version MaxiMailer GUI version Firmware Firmware Firmware Am4HeadWithGUI PD V3 Am4PlusPC PD V3 A x Amd4HeadWith GUI 4 0 4 x x am4 x am4 x am4 Installation File Rev 2 0 1 0 Upgrade file V2 0 1 0 1 bin Standard Am4Feeder V3 4 x x am4 4 V3 4 x Am4Feeder_V4 0 x x am4 Insert Feeder x am4 2 bin Tower Insert
47. gurations 2 modules Mlasimum and throuhput 3750 hr elas Code 140288 Standard feeder plus 2 Plate Folder H02BA Standard feeder plus thin 3Plate Folder HO3AA Tower feeder plus 2 Plate Folder H09BA Tower feeder plus Ibin 3Plate Folder HOSCA Sbin3PlateFolder Hotes A prefiz before the Product Code denotes 115 60Hz E prefiz before the Product Code denotes 230W 50Hz prefiz before the Product Code denotes 115 50Hz Y prefiz before the Product Code denotes 230 60Hz 1404 44 Standard Feeder plus 3 Plate Folder 1405 44 Tower feeder plus 3bin 3 Plate Folder Options See Upgrade Kits Table 6 2 0 Standard Maximailer GUI machine Configurations Upto 4 modules configuration and throughput 4500 hr 14305 Mlasimailer Head Unit 3 0 MaxiMailer Plus PC machine Upto 8 modules configuration and throughput 4500 hr 4314 4 Plus Head Unit 12 02 07 Page 1 74 Technical Tips INSERT HEAD Module Product Codes 1440E 144066 144008 1440 144000 440CE Barcode Vertical Bottom Read End Module 1440 Barcodes Horizontal Bottom Read End Module Barcode Vertical Top Read End Module 1840221 Barcode Horizontal Tap Fead End Module 14400 Barcode Vertical Bottom Bead Inline TABLE 1 Product Code j 14504A 14524A MZ0EA FrankerLink j 142155 Franker Link See table 2 1
48. k all track transport and drive belts for wear and fit Clean and check function of all solenoids Check all job settings are correct for envelope and insert sizes Check and clean wetter sponge and tank if necessary Check and test function of all feeder folder units 10 Test run the machine with customer s stationery 11 Clean the customer s machine so it is presentable 12 Complete the LOG book fully THE TRIM PROCEDURE IS MANDATORY WITH EVERY VISIT Please make sure that you fully complete your worksheet 12 02 07 Page 1 42 Technical Tips INSERT HEAD Module A 25 Cleaning sensors and Calibrating in Supervisor Mode 123 Engineers to provide additional training to Operators to highlight ALL paper path sensors that may require cleaning e g on the head unit Envelope Deskew Sensor etc Also provide training to the Supervisor on how to calibrate sensors after cleaning within Supervisor Screen implemented on firmware version V4 0 0 12 or V3 4 0 12 onwards A 26 Motor Stall Error 08 50 or 1050 or slow paper speed 1061 Ver 3 Problem resolved on machine effective from Sept 05 If the above errors have occurred initially refer to previous tech tips for corrective actions If problem persists conduct the following for each module excluding the head unit a Connect the debug lead and using Am4go check the trace is being received b Run up motor for a short period and then press STOP Note this can also
49. lication Standard fingers will inevitably catch the window edge as they enter the envelope throat The High Window fingertip has a start position on the window and will therefore will not catch it All high window envelopes should be fully trialled before acceptance as some versions of high window envelopes will not run with either Standard fingers or High Window fingers Parts required are 1x B9071A High Window Finger LH 1 B9070A High Window Finger RH 2X E5055A 3 5mm D1500 E Clip spare for use on finger pin 1x E5074A 3mm x 8 long dowel pin see fitting instructions Finger Replacement Instructions a Remove Drives Side Cover 3 screws Remove Operator Side Cover below Control Panel Assembly 3 screws Remove Control Panel Assembly disconnect 2 ribbon cables and remove 5 screws b Remove Envelope Feeder Assembly disconnect ribbon cable and interlock connector remove 6 screws Replace fingers with alternatives It is better to do this one at a time The technique is to remove the small circlip then use a 3 diameter x 8 long pin to push out the finger pin this short pin then ensures that the small spring stays in place on the finger body Replace with the new finger make sure the spring tang goes through the rectangular hole in the finger and use the finger pin to push the 3dia x 8 pin out Retain with small circlip Check that the new fingers are assembled correctly and they rotate freely on the finger pins d
50. lso the receiver sensor is replaced with a longer version part number 182 345 preventing water spillage from the above contaminating the sensor connector Other wetter checks required a Check and ensure wetter is setup as per technical Bulletin 1420 101 at first instance b The wetter sponge should be 28mm from base to top it should be not too tight or loose and follow profile of the metal Check that the wetter tank assembly is setting level in the machine and 4 6mm of fluid is maintained d The amount of envelope flap that is wetted ve more wetting can be adjusted In steps of 1mm If over wetting this figure can be reduced New Ski Bridge 12 02 07 Page 1 19 Technical Tips INSERT HEAD Module 12 02 07 Page 1 20 Technical Tips INSERT HEAD Module To set the adjustment of the wetter beam setting gauge 740 must be ob tained This is a shaped aluminium bar that sets the adjustable stops correctly Wetter beam Setting gauge Zero play 40 spring Up solenoid Adjustable stop Down T solenoid Fig 15a Setting procedure refer to Fig 13a above 1 Remove lower both side covers section 3 1 2 2 Slacken the screws on the adjustable stop each side Remove the wetter tank and replace it with the setting gauge C 403A 3 Hold down the wetter beam to that it contacts the guage then slide the adjustable stops so that they contact the spigots on the beam Tighten the scr
51. odule Two module stand Three module stand Four module stand Five module stand Six module stand Seven module stand Eight module stand Head stand unit ang mie apg Franker Table 3PF Pick Up Shaft Assy silicon ture Core PISIA Tarr Grab E2585 H PAU Envelope Opener Assembly For curly Haps a ee ee 2 77 TABLE 8 DataCard Product Codes Anti Static Brush Feeder Diss DiC Maxi Combo 42064 145355 EDIC 15 5 Brea Oyverquide can assist Feeding of BREs From Insert Feeder OLSA Maxi Plus Head amp stand 432535 875055 Special Feeder can assist Feeding of 2 Fold Forms From Insert DLiataCard Insert Feeder and stand amp 352415 BrT3414 Special wether Guide DCard Intelligent Fdr Horiz BC Btm Ad 432474 5 Hi vindaw Envelopes Finger GSD LIC SHDE DOIMA 14535 5 Datacard Turnover InterFace TABLE 9 CardFolder Product Codes 143075 Inzerter Card F older stand TEAOP A 2Plate Folder stand 1450F4 Insert Feeder stand 4522F A e Hopper Insert Feeder stand 144 4E Card Falder module 12 02 07 DiCard Intelligent Pdr Horiz BC Top Ad amp 32415 Hi windaw Envelope Finger LH DataCard Tower Feeder and stand A32414 Backztop Roller Light Dongle Far SE PMaxilvlailler with z Plate Folder as 2nd module Extended Features Dongle For Std Maxi amp Maxi Plus Dongle For Plaxilvlailer with 3 Plate Folder az sole
52. ope skewing into the sideguiderz jthen initi all yremove and reload entire hopper If problem persiststhen re adust the side qudesto give slighthragreater clearance The use ofthe tractor shoud help to fatten the cured envelopes atthe point afzeparation to prevent this Mote the twist on the envelope should not be more than 174 5mm when placed dat Separator spring action locked Separator adjustment is mow limited reed to back offthe separator lock prevent any separator nuts before anyadjustments can made Ma operator intervention movement dou Thists allowed out by adjusting the 2 lackruts to the underside of he bracket see fig 2 Separator pad 20 5mm Remove the outer lower tyres fmm he pre ed assembly see igure 3 Standard Feed shat re ATO SA see igure 4 Separator pad mm or less If poor pick up experienced it iz Separator pad alu ays best to ensure that side guides ovedap 0 4mm are not set too tight and restrictive on he envelope pack Loosen separator ifthi doesrit help orleadsta doubles thentry altematiwe rollers and then the tractor Separator pad ovedap D Smm Current options include sotted silicon types Mote the joggler is fitted standard to the outside E 15 essential that bumps in line across the shat othenuise this will encourage envelope skew 1 Hopper capacity is ver
53. ow Pipe and can drop down onto the Wetter Reservoir and into the base of the unit Excess fluid problems can be caused by a Incorrect specification of wetter foam fitted to centre section of Wetter Tank supply error If the incorrect grade of foam is fitted then excess fluid is drawn up to the wetting surface Overwetting and fluid carry through results in excess fluid dripping down the rear face of the Wetter Tank and accumulating in the Tank Channel It can then drip into the base of the unit The correct foam has a larger cell construction recognisable by a pitted rather than a smooth appearance Replacement parts Wetter Foam Edge G0135A x2 Wetter Foam Centre G0136A x1 b Incorrect setting of the Wetter Beam down position The Wetter Beam should be set so that it does not contact the wetted foam ideally it should be set with a nominal 1mm gap between the base of the Wetter Beam and the top of the Wetter Foam The gap is set by adjusting the 2 Wetter Adjust Plates R2191A on either side of the wetter section A Wetter Setting Block C7403A is available This is placed in the Tank Channel and used to set the correct down position of the Wetter Beam 12 02 07 Page 1 14 Technical Tips INSERT HEAD Module The Overflow Pipe C3482A has been re designed to direct any drips from the Tank Channel back into the Wetter Reservoir Replacement parts Overflow Pipe C3482A issue 2 or later O Ring Seal E0235A Nut M12 x 5mm P2375A
54. ox 4 Click SaveToFile and wait until the scrollbar is completed This file is stored under your am4go application within a Jobs folder Note down the file name and location if required xxxxxx txt file Check to ensure the file is stored as mentioned in above folder 5 Power Off ON 6 Download new firmware as per normal starting from the last module and working forward towards the head T Power Off ON 8 Re connect debug lead to head unit and type XR am4go send box and click send to accept This will reset all nvram Note that the GUI will display Reconfigure machine Note DO NOT RECONFIGURE MACHINE 9 Power Off ON 10 Re connect debug lead to head unit then re click Jobs Settings to bring up stream Jobs and Settings box 11 Click LoadfromFile select file as 1 1 4 and wait until the all record have been streamed back into the machine 12 Switch off machine and re start Notice that machine will have reconfigured and retained all settings and jobs Not Applicable if already on V3 1 xx or later 12 02 07 Page 1 59 Technical Tips INSERT HEAD Module NOTE if you are running firmware version V3 2 0 5x then you will require a special version V3 2 0 5STR for streaming Stream Jobs and Settings Save jobs and settings from machine to file Load jobs and settings from file to machine Abort proceedings Error 5 Access is denied 12 02 07 Page 1 60 Technical Tips INS
55. pprox Stop posn for envelope to tilt upwards and reversing 12 02 07 Page 1 62 Technical Tips INSERT HEAD Module A 45 Downloading via head To download directly to the head unit via the RS232 connector Right Hand Side Socket located at the rear of the machine the following actions are required Modify debug box 184 176 D Type Plug connections Pin 2 BLU and Pin 3 Red as shown below Remove the Main Cover Lower B7745T and connect the serial connector on the Head PCB J14 Connect modified lead as per a to rear of machine for downloading and diagnostics SET LUG CUNNECTI CSULDER N RE LU wants OOOO 12 02 07 Modify this Plug as shown below MODIFIED WIRING CHANGE PIN 2 B UE gt PIN S SCSINE Page 1 63 Technical Tips INSERT HEAD Module A 46 MaxiMailer Plus PC set up Instructions 1 INSTALLATION FOR DEMONSTRATION ONLY e g LAPTOP 1 1 CAN DRIVER INSTALLATION 1 1 1 In folder 2005 double click CDSTART EXE 1 1 2 Click ENGLISH or DEUTSCH 1 1 3 Click Driver Installation 1 1 4 Click VCI Version 2 16 for Windows 9x Me 2000 XP Service Pack 2 1 1 5 Follow the instructions and install the drivers 1 2 MAGO INSTALLAT
56. r for improved clearance to Monitor Post 7 Soft Start interlock to protect mains switch from high inrush current 8 USB PC connection change PCI card now obsolete 9 R7968A Reflective sensor bracket sensor falling out changed to improve the snap location of the reflective sensor 10 E0446A plastic wiring clip to be used instead spring type B01060A to retain ribbon cables throughout the machine 11 New fixing arrangement for the re modelled ELO touch screen monitor see manual section 4a 36 12 Hank bushes added to secure idler post C2586A There have been reports of screws locating the idler posts C2586A shearing in the field This seems to be to a combination of the posts being attached un square to the chassis putting the screw under stress and rust due to water leakage from the wetter area of the machine The use of the hank bush should guarantee that the posts are attached square to the chassis and allows for the new stainless M4x35 Pozi Pan head screw E2833A without pre tapping the chassis 13 Most Idler Post fixings changed to self clinch threaded bushes to prevent screw failure Tolerances amended to reduce side float 14 B8744A T5671 Front Latch Plate change to profile Reason the tip of this plate can touch a bridge clamp on the MaxiMailer chassis causing unequal seating of the Collate Pocket Clamshell which can cause envelope skewing problems 15 C8203A Feed Roller optional A softer natural
57. re calibrate sensors Automatic track purging at start up and job change Engineer Advanced Automatic settings Faulty group removal at closer non Hopper extended refill timer Far loading an the Fl Engineer diagnostics of clutches solenoids etc Auta end on prime empty Mate 2 Contest Sensitive help on Fault screen Conveyor batch pulse control modes jog step and pause time control Total batch Flexibilit Sensor Failure tolerant run made Far insert Feeder Buick Job Count reset en GUI press stop and then tick Cascading on Tower Insert Feeders UpfOown x 1 2 Cascading an Adjacent Standard Insert Feeders e en Cascade from stations 152 ar o x Lo Lx Flexible feed mades x x SL NE MEM Nw NEN a a ae NH EE o CN NN LLL EEE esll 11 PEEP EEE EEE PEEP EE EET EEE babel fetal alse E ER RISE Enhanced calibration made Cal Check Go Mo Contirmation x x xk xk x x x P wr as s Lelel 2s o Cascading from modules 1 2 and 3 jnan OMR x x x x x
58. rning off the AC motor The operator is not affected as in general all dangerous moving parts are stopped on the opening of covers The exception to this is the Two Plate Folder module This is dealt with later Identifying the problem To identifying this problem enter Supervisor menu enter engineer password select Insert Head or a Module select Drivers and then turn on the Main motor Now open a cover if the AC motor continues to run you have this problem The Two Plate Folder Module This module has been highlighted because the fold rollers are not clutched and could be a hazard to the operator in the unlikely event the PSU is replaced with an old build All Two Plate Folder modules shipped from factory have been fitted with latest build of boards and PSU and do not exhibit this problem IMPORTANT The PSU on a Two Plate Folder must only be replaced with a PSU carrying a yellow sticker near the mains cable entry point Failure to do so could result in a hazard for the operator 12 02 07 Page 1 41 Technical Tips INSERT HEAD Module A 24 Engineers Trim List Procedure List of actions checks to be carried out by Engineers is highlighted in this document A copy is attached below 9 TRIM PROCEDURES Inspect Machine for damage and safety Check software versions and mandatory updates Clean and calibrate sensors in all modules Clean all fold rollers and inspect for wear or damage Chec
59. s There have been instances of the flap missing the opener due to the curl on the flap caused by excessive glue At the first instance check set up of the opener as shown below A when the deskew rollers are compressed when the pocket is closed ensure opener edge is NOT touching deskew rollers B ensure this edge is just clear when the opener is in the down position thus allowing the drive roller to turn freely If problem persists then cut a piece of Mylar 11 about 32 to 33mm in length depending on how much overhang is required to catch the flap as shown below Round or taper the corners that will overhang Then using double sided tape E0188A secures the Mylar piece to the Opener Assy utilizing the natural curve of the Mylar Mylar cover fitted and extended at this point by 1 2mm Deskew Rollers Opener adjustment can be made here 12 02 07 Page 1 49 Technical Tips INSERT HEAD Module A 36A Flap catches on the Envelope Opener Jan 2007 Update A 37 Upgrading MaxiMailer to MaxiMailer Plus For upgrading a MaxiMailer GUI version to MaxiMailer Plus PC version please refer to the Fitting Instructions K4039A A 38 Error 57 Version 3 and upwards 5v supply low This error can cause other faults like for e g code 202 clear collate pocket this implies a possible short that is taking the supply down Corrective actions check the relevant sensors collate pocket collate po
60. s Effective Effective to Bulletins Number from if applicable 24 1 42 Engineers Trim List Procedure 0905 25 1 43 Operators to be advised on Cleaning Sensors 05 Y A26 1 43 Motor Stall Error 08 702102 June05 v A27 1 44 Envelope Deskew Sensor needs cleaning error 05 Feb06 y Error 56 version 3 Excessive Current Od05 o A29 1 46 Power Supply 26V low error 1054 on version 3 Oct05 o A30 1 47 MaxiMailer Installation Instructions o 31 1 47 MaxiMailer Plus Installation Instructions A 32 1 47 Version downloading guidelines document A 33 1 47 Error 60 version 3 sensorstucklow Oct05 34 1 48 Shipping Modules separately ApilOob 2 A35 1 48 1 25T pulleys nowallplastic OctO3 05 A36 1 49 Flap catches on the Envelope Opener 12 02 07 3 Page 1 3 Technical Tips INSERT HEAD Module MaxiMailer Service Engineers Technical Tips Documentation Jan 2007 INSERT HEAD Module 1430 1431 and variants Technical Page Main Area INSERT HEAD Date Date Technical Mandatory Tip Number 1430 1431 and variants Effective Effective to Bulletins applicable
61. se from these mechanisms Check pins in the gears are not loose protruding and rubbing against clutch brake 12 02 07 Page 1 15 Technical Tips INSERT HEAD Module A 12 Insertion Crashes due to narrow inserts Field Option Running narrow inserts If running a mixture of narrow and wide inserts there is potential for the narrow inserts to drop down from the edges which result in crashes in the envelope The preferred option is to sandwich the narrow insert amongst the wider documents so that the above does not occur However if this is not possible then tape can be fitted as shown below in 2 positions as shown below Alternatively Wide Fingers and Collate Pocket Side Guides A3287A can be fitted which will allow a maximum document width difference of 1 1 4 Once the wide fingers have been fitted they will require re calibrating To do this firmware version 3 1 0 4 or later must be loaded into the insert head to allow the fingers to be re calibrated to 210mm Tape to support pack in collate pocket the tapes need to be 45mm long x 20mm wide and bent upwards 30mm from one edge Double side tape the remainder and fix inboard of the collate pocket side guides making sure that they do not interfere with the fingers and collate pocket side guides Alternative field fix spring steel can be secured to bed of collate pocket 12 02 07 Page 1 16 Fit tape in collate pocket tape 70mm long x 35mm wide
62. sert towards wetter area this can be adjusted if required c Engage and disengage fingers in Engineer to ensure both solenoids are pulling in and that the stroke is balanced and setup 4mm from plunger slot to solenoid body see photo 1 Note this can be reduced if required 4mm from bottom of plunger slot to solenoid body d Check to see if the envelope is not central to the fingers when sitting in the insertion area To test for this mark the extreme edges of the external fingers on the chassis bridge that they sit against Run an envelope though the system by hand and stop it at the insertion area The finger position marks on the chassis can then be used to check their position relative to the envelope If you also find this to be incorrect can you please contact us so that we can determine an appropriate course of action Instructions Program a job to set up the fingers to run e g 229mm envelope with 210mm wide insert or form ii Run the job to allow the machine to set up for the correct default fingers and collate pocket e g for the above job the outside fingers will set up to 218mm and collate pocket to 212mm iii Manually pull the fingers IN to help you mark up the outer finger position on the envelope bridge Then hand feed an envelope to the stop posn see point e and mark on the envelope outer finger positions to allow checking for centred finger position to envelope 12 02 07 Page 1 22 T
63. t MaxiMailer MaxiMailer Plus Service Manual will be available on the website for download This will be updated at regular intervals A 33 Error 60 Version 3 sensor stuck low collate pocket entry or input conveyor Problem resolved on machine effective from Sept 05 This is caused by direct sunlight or lighting above over the head unit which effects the above sensors at switch ON At the first instance move the machine to prevent this from occurring ref installation instructions If this is not possible then a shield can be fitted as shown below The cover B7502F Issue 2 has been redesigned and can be fitted if required optional With regards to the input conveyor again Mylar tape can be fitted as shown below Mylar cover fitted Also please note during calibrating the sensors ensure all the covers are closed 12 02 07 Page 1 47 Technical Tips INSERT HEAD Module A 34 Shipping modules separately Individual modules for MaxiMailer are to be shipped separately either for installation on site or for stock From software version 3 1 x x onwards it is important that each module on the machine is running the same software version This applies to insert head standard feeder tower feeder and 3 plate folder Only the first 2 digits of the version number need be the same the second 2 digits do not need to match In order to identify the software version each module package carries a label on the outside This
64. ting El El E amp E gm gm ve v x x Forms Sequencing El El gl ma El gm m Pel rl x x Grouping OR or Barcode multiple modules x Pal x x x Matching between teed modules Easy re programming of item id to hopper assignment a x ox Different barcode symbologies and grouping schemes can be offered specials 6 1 aes Features available on the Plus additional cost on the Std ze lele le lel elel Barcode Reading Label on FIRST page printed ONLY last page Fed x z mm vc PT wr Extended pitches THU 3 8mm 4mm and 5 3mm oe pe wf LY OMA reading Invisible Gate Mark x x x x x x x B v z OMA reading Demand Feed feed when mark is present x x x x x E v OMF reading Force Fold zx x x x F F OMF reading Local Matching see note S x x x x x v v Mazimailer Plus eztended Features available at additional cost Datalog ALL pages pepe te fete fie fe bef ae PFE Murmerical Barcode Beading 2al 5 x zr x x A Data Logging Software Pack age Em m Log barcode labels read atinput x x x x m Log groups at output Log errors x Gen
65. tioaz they tall retira TRI home are the etim zprigteszkon zee 11 2 book tor stk lig the mb Fingers digging liio aotpiilig ck aw by ThE BUENA Check dirig mache niin ing lope ti marks oa the e fee e 12 The corectie action 0 the Tiger tip or replace the titty niger 12 02 07 Page 1 33 Technical Tips INSERT HEAD Module Datacard Machines Ervelope vany fram pkup mib ONLY n miller a Tala sihi ffurn ACS fighter seing dum CVV lapse sling Lock Separar wing the ck oh skip 12 02 07 Page 1 34 Technical Tips INSERT HEAD Module Figure 5 Outer finger setting set correctly far the envelope width Figure 6 Middle fingers opening the throat of the envelope p Look through the viewing hole both sides with the fingers engaged to ensure middle fingers are going in cleanly 18 ES LI cieasa Ing ip be V pasii ngd within ar amante of natch in bridge Locking thmagh the viewing hold the finger ais on oF behind Tha give pa cras eli 12 02 07 Page 1 35 Technical Tips INSERT HEAD Module
66. tray 3 plate folder See table 3 3 tray 3 Plate folder See table 4 2 Plate Folder See table 5 OMA arcode Feeder See table B Mate Shen more than 2 heads are Fitted an Expansion Kit 184 131 required 2x 184 131 are required For more than 4 OMF heads ar BC Tray 1 1ehannel 1 Trag 3 Plate Folder Modules and Options TABLE 2 Head kit APA agaga 1442 44 1Feed Tray 3 Plate Folder HS SERT Accumulator Bed part na A3252A or BC Tray 1 TABLE 3 1 channel Y 3 Trag 3 Plate folder Modules and Options Tray 2 i channel IS OMA 3 Trays 3 Plate Folder 15 OMIA 3 Trays 3 Plate Folder IS OMIA 3 Trays 3 Plate Folder Essen E EN P 12 02 07 TABLE 5 Code EM5IEA EM5IBE EM5IDA TABLE 6 Product Cade Pa 3 Elate Folder OMA upgrade A32324 3 Flate Folder Horizontal Barcode upgrade kit 5 tra 432934 3 Plate Folder Vertical Barcode upgrade kit 3 tray AS30345 2 Plate Folder OMA Upgrade Kit 433104 Folder Feed Civerquide Light Kit 433115 Folder Feed Overguide Heavy Kit A337 Accumulator Clutch Upgrade Kit ES14014 5 Plus PICS Software ES14024 4 Plus Qatalogging Software Single module stand AF O44 570505 6 70515 Af 253A A255 532395 532095 DSO Technical Tips INSERT HEAD M
67. w envelopes Optional FIELD OPTIONS A10 1 15 Envelope crashes at deskew rollers OctO3 Sept04 v narrow inserts OPTIONS ndi Envelope opener stop breaking 4360 Oct 03 Aug 04 14 1 18 Red Loctite on Operating Handles that have Oct 03 Mar 04 become loose A 15 1 18 Wetter and Finger solenoids plunger wear causing Oct 03 Jan 05 insertion and wetter crashes Clutch Pins falling out during running causing loss Oct 03 Aug 05 of drive 17 Wetter Sensor getting wet resulting in Wetter Jam Oct 03 July 05 ans 36 37 or 38 1 22 03 JuneO5 Y _ 128 O Belts jumping erratically Head Upper clam Oct03 05 Y 12 02 07 2 Page 1 2 Technical Tips INSERT HEAD Module MaxiMailer Service Engineers Technical Tips Documentation Jan 2007 INSERT HEAD Module 1430 1431 and variants m assembly A7041A A 20 1 37 Envelope Shim on Flap Grip Roller Assembly Oct 03 m foo 7 A7072A installed incorrectly Feed shaft assembly pin becoming loose Oct03 05 A 22 1 40 Sealer Closer Assembly A7046A black tape mE Optional ELEM FIELD fitted to prevent light affecting sensor OPTIONS Cover Interlocks AC Motor Fails to Stop on Feb 06 1420 100 opening of the covers 4 Technical Page Main Area INSERT HEAD Date Date Technical Mandatory Tip Number 1430 1431 and variant
68. y iii Yellow spring s G1116A can be fitted onto the lower rollers as per a ss Envelope Shim on Flap Grip Roller Assembly A7072A 12 02 07 Page 1 37 Technical Tips INSERT HEAD Module Previously envelopes could distort and catch on the assembly at various points The bar that holds the small diameter grey flap grip rollers has been modified to prevent the roller from locking and forming flats after time Other mods include Edge deflector B7714A improved to give better guidance into flap grip area Envelope Defector R2175A improved to give better guidance into flap grip roller Envelope guide bar C9436A Chamfers added to cutaways to remove potential catch points Guide tapes added to envelope feed to prevent fingers catching on edge of wheel cutouts Flap grip roller bar C4363A bearing shoulder changed to remove potential bearings snag Improved guidance 12 02 07 Page 1 38 Technical Tips INSERT HEAD Module A 21 Feed shaft assembly pin becoming loose and damages ribbon cable Problem resolved on machine effective from Sept 04 Check and ensure pin E5078A in the Envelope or Insert feeder Pick up shaft is not working loose see below If so it will damage the ribbon cable and short circuit the relevant sensors The corrective action in the field is to apply a dab of Green Loctite around the pin and any excess to be cleaned off to ensure the pin does not become loose
69. y dependent upon envdope types feeding probleme are encountered itis best to try reducing the amount of envelopes loaded note this is particulary applicable on twisted envelopes For optimum load 300 envelopes max 2 tis wew importantthat both separator pads are set atthe same position Tt shouldnt be uzed to try and overcome skewing Mote an uneven separator ard sometimes separator that is zettoo tight will detn the ervdope resulting in crashes turther dow 3 lithe separator is set wew tight maybe necessaryto overcome doubles ete the deskew walue is ze to high this can result in too much diwe on the ere ope and it will detom bad yas it enters the deskew rg lers best to start with deskew values setto Page 1 32 Liz Technical Tips INSERT HEAD Module Guidelines for qood Envelope Insertion Sa Up Coton Acton Required Ce sc ription Se taid lock she QI Seto zmm imm eer E Hej On ky ope i 1pclearaacez e aue skew kD the cide quide Once zet lock both sides lip position aad check by placliga kaidi lof l tie kopper Torclearaiee aad Se parrain at To be s teuei aad equal approx D 5mm oue rap death Ge ie t E setting ler pes ardslighty beaver with the Tacir ip E ee dy azzemb by l add tow the separator cai be locked l see
70. ysis of all system components at power up or reset After upgrading to Version 3 firmware you may start getting error 1054 26Volt Supply is low There is an adjustment that can made on the module Power Supply board to adjust 26VDC This potentiometer VR1 see picture below is very sensitive Very small movements can make 5 or more volt adjustments Adjustments can be checked via the GUI display or using a meter To do the adjustment with a meter dis connect the 24v cable from power supply to the module board Measure voltage on the power supply across YLW pin1 and BLK pin5 or 6 this should be about 26v 6 Adi i amp A m 14 i Tb NP n n Mar APA ay file Tate Sk 31 VR1 26VDC Adjustment POT 12 02 07 Page 1 46 Technical Tips INSERT HEAD Module A 30 MaxiMailer Installation Instructions Updated Installation instructions for Maxi have now been updated to include Maxi Plus see latest Service Manual Auto4s1 A 31 MaxiMailer Plus Installation Instructions MaxiMailer Plus Installation Instructions have also been created Ref 4040 document Also existing is K4039A MaxiMailer to MaxiMailer Plus upgrade A 32 Version 3 downloading guidelines document The latest version June 05 can be found on the PFE Technical Web page Please read and implement before downloading new MaxiMailer firmware Note During November 2005 the lates

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