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Secap USA, Inc.
Model SI 1000
SERVICE MANUAL
The title, copyright and all other proprietary rights in this document are vested in Secap USA, Inc. and no part of it may be reproduced in any form without the written permission of Secap USA, Inc. The document is for the exclusive use of the person to whom it is issued; its contents are confidential and must not be disclosed to any third party or used for any purpose other than in the proper conduct of Secap USA's business and it must be returned to Secap USA, Inc. immediately upon the person ceasing to be associated with Secap USA, Inc.
© Secap USA, Inc., 2002
SI 1000
Table of Contents
SECTION
PAGE
1.0 1.1 1.2 1.3 1.4 1.5 1.6
INTRODUCTION ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Purpose ................................................ Equipment Covered ... ... ... ... ... ... ... ... ... ... ... ... ... ... Related Publications ... ... ... ... ... ... ... ... ... ... ... ... ... ... Contents ................................................ Safety Summary ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Equipment Safety ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
1-1 1-1 1-1 1-1 1-2 1-2 1-4
2.0 2.1 2.2
SPECIFICATIONS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Material Specifications ... ... ... ... ... ... ... ... ... ... ... ... ... Machine Specifications ... ... ... ... ... ... ... ... ... ... ... ... ...
2-1 2-1 2-4
3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21 4.22 4.23 4.24 4.25 4.26
THEORY OF OPERATION ... ... ... ... ... ... ... ... ... ... ... ... Introduction ................................................ Single Sheet from Sheet Feeder A1 into an Envelope ... ... Single Sheet from Sheet Feeder A2 into an Envelope ... ... Two Sheets from Sheet Feeder A1 and A2 into an Envelope Two Sheets from Sheet Feeder A2 (Accumulation) into an Envelope Jobs that run an Insert ... ... ... ... ... ... ... ... ... ... ... ... ... Fold Only ................................................ REMOVAL & REPLACEMENT ... ... ... ... ... ... ... ... ... ... Right Hand Side Cover ... ... ... ... ... ... ... ... ... ... ... ... ... Left Hand Side Cover ... ... ... ... ... ... ... ... ... ... ... ... ... Exit Idler Assembly ... ... ... ... ... ... ... ... ... ... ... ... ... ... Stacker Cover ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Envelope Feeder Cover ... ... ... ... ... ... ... ... ... ... ... ... Control panel (User Interface) ... ... ... ... ... ... ... ... ... ... Rear Cover ................................................ Top Cover ................................................ Insert Feeder Assembly ... ... ... ... ... ... ... ... ... ... ... ... Envelope Feeder/Exit Assembly ... ... ... ... ... ... ... ... ... ... Sheet Feeder Assembly ... ... ... ... ... ... ... ... ... ... ... ... Inducer Cover ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Inducer Assembly ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Power Supply Board ... ... ... ... ... ... ... ... ... ... ... ... ... ... Disconnecting the Upper and Lower Frames ... ... ... ... ... Envelope Separator Stone Assembly (Retard Pad Assembly) Separator Belt Carriers ... ... ... ... ... ... ... ... ... ... ... ... ... Exit Roller Shaft and Exit Sensor ... ... ... ... ... ... ... ... ... Sealer Idler Roller ... ... ... ... ... ... ... ... ... ... ... ... ... ... Sealer Roller ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Moistener Deflector Assembly ... ... ... ... ... ... ... ... ... ... Idler Support Bar ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Flapper Roller ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Flapper Assembly ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Idler Support Frame Assembly ... ... ... ... ... ... ... ... ... ... Orbital Roller ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
3-1 3-1 3-2 3-4 3-5 3-6 3-8 3-8 4-1 4-1 4-1 4-2 4-2 4-3 4-3 4-3 4-4 4-4 4-5 4-5 4-5 4-6 4-7 4-7 4-8 4-9 4-9 4-10 4-10 4-11 4-11 4-11 4-12 4-12 4-13
i
Table of Contents
SI 1000
SECTION
PAGE
4.27 4.28 4.29 4.30 4.31 4.32 4.33 4.34 4.35 4.36 4.37 4.38 4.39 4.40 4.41 4.42 4.43
Insert Feeder Separator Block ... ... ... ... ... ... ... ... ... ... Insert feeder Belt Carrier Assembly and Transport Shaft ... Main Cam ................................................ Fold Rollers ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Finger Frame ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Moistener Nip Frame Assembly ... ... ... ... ... ... ... ... ... ... Insertion Frame Assembly ... ... ... ... ... ... ... ... ... ... ... ... Convenience Feeder Shaft ... ... ... ... ... ... ... ... ... ... ... Sheet Feeder A1 Shaft ... ... ... ... ... ... ... ... ... ... ... ... ... Lift Arm and Gate Assembly ... ... ... ... ... ... ... ... ... ... ... Logic Board ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Sheet Feeder A2 Top Metal Cover ... ... ... ... ... ... ... ... ... Sheet Feeder A2 PCB ... ... ... ... ... ... ... ... ... ... ... ... ... Sheet Feeder A2 Paper Sensor ... ... ... ... ... ... ... ... ... ... Sheet Feeder A2 Main Drive Motor ... ... ... ... ... ... ... ... ... Sheet Feeder A2 Drive Shaft ... ... ... ... ... ... ... ... ... ... ... Sheet Feeder A2 Feed Shaft ... ... ... ... ... ... ... ... ... ... ...
4-13 4-13 4-14 4-15 4-16 4-16 4-17 4-17 4-17 4-18 4-18 4-18 4-19 4-19 4-19 4-20 4-20
5.0 5.1 5.2 5.3 5.4 5.5 6.0 6.1 6.2 7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 8.0 8.1 8.2 8.3 8.4 8.5 8.6 8.7
ADJUSTMENTS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Envelope Separation ... ... ... ... ... ... ... ... ... ... ... ... ... Insert Separation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Sheet Feeder Lift Plate Tension ... ... ... ... ... ... ... ... ... ... Changing the Display Language ... ... ... ... ... ... ... ... ... ... Envelope Park Position - Field Setting ... ... ... ... ... ... ... ... TROUBLESHOOTING ... ... ... ... ... ... ... ... ... ... ... ... ... Error Codes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Service Diagnostics ... ... ... ... ... ... ... ... ... ... ... ... ... ... INSTALLATION ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Unpack and Check ... ... ... ... ... ... ... ... ... ... ... ... ... ... Locate the Machine ... ... ... ... ... ... ... ... ... ... ... ... ... ... Connect and Turn On ... ... ... ... ... ... ... ... ... ... ... ... ... Fill Moistener ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Load Envelopes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Load Sheets ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Program Job ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Run Test Job ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Complete the Installation ... ... ... ... ... ... ... ... ... ... ... ... DIAGRAMS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Machine Layout and Paper Path ... ... ... ... ... ... ... ... ... Component Locations ... ... ... ... ... ... ... ... ... ... ... ... ... Schematic - Logic PCB ... ... ... ... ... ... ... ... ... ... ... ... ... Schematic - Front Distribution Board ... ... ... ... ... ... ... ... Schematic - Rear Distribution Board ... ... ... ... ... ... ... ... Schematic - Sheet Feeder A2 Distribution Board ... ... ... ... PCB Layouts ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
5-1 5-1 5-2 5-3 5-3 5-4 6-1 6-1 6-6 7-1 7-1 7-2 7-2 7-3 7-3 7-3 7-4 7-4 7-4 8-1 8-1 8-2 8-4 8-5 8-6 8-7 8-8
ii
Office RightTMMailer SECTION 1.0 INTRODUCTION 1.1 PURPOSE
1. Introduction
This document provides the information necessary to support the installation and site repair of the SI 1000.
1.2
EQUIPMENT COVERED
This manual applies to the SI 1000 and its optional Second Sheet Feeder.
1.3
RELATED PUBLICATIONS
The following Secap USA publications apply:
SI 1000 Operating Guide - USA SI 1000 Install Guide - USA SI SI 1000 Sheet Feeder 2 Install Guide SI 1000 Parts Guide
1-1
1. Introduction
1.4 CONTENTS
This manual is organised as follows: Section 1--Introduces the manual. Section 2--Lists material and equipment specifications. Section 3--Briefly presents the theory of operation. Section 4--Presents removal and replacement procedures. Section 5--Gives adjustment procedures. Section 6--Lists troubleshooting procedures. Section 7--Provides installation, setup and check-out instructions. Section 8--Contains schematics and other diagrams.
SI 1000
1.5
SAFETY SUMMARY
Warning messages are used throughout this manual to alert you to potentially hazardous conditions. These warnings are explained below. WARNING -- calls attention to improper practices that could cause injury. CAUTION -- calls attention to improper practices that could damage the equipment or the material being run. IMPORTANT -- calls attention to practices that could adversely affect equipment operation, if instructions are not followed exactly.
You must familiarise yourself with proper procedures and methods before you install, operate or service the equipment to avoid personal injury or damage to the equipment. If you are responsible for training service personnel or equipment operators, it is incumbent on you to explain safety precautions to your students and encourage safety awareness. The following is a list of general precautions which cannot be overemphasised:
HIGH VOLTAGE is present at certain points in the equipment. INJURY or DEATH could result if you fail to observe safety precautions. Know how to turn off power in the work area and how to summon help in case of emergency. Do not work on equipment under power unless absolutely necessary. When working on a live circuit, use extreme caution. Don't grasp two sides of a live circuit at the same time. Always use the right tools for the job. Treat every circuit like a gun which may be loaded. It may not be "live", but be sure. Check with a neon tester, a voltmeter, or simply unplug the machine. Use one hand when reaching into a circuit. By keeping one hand free, lethal current is less likely to pass through vital organs. Observe this rule when connecting or disconnecting plugs or leads, and when making any adjustments on a live circuit. Don't underestimate the danger of shock: 1 mA (1/1000 ampere) is uncomfortable; 5 mA (1/200 ampere) is dangerous - the victim may jump back and be injured; 12 mA (1/83 ampere) causes hand muscles to contract - the victim cannot free himself; 24 mA (1/40 ampere) has proven fatal; and 100 mA (1/10 ampere) is likely to be fatal.
1-2
SI 1000
1. Introduction
Don't reach into a circuit with metal tools, or while wearing rings or a watch. Even in low voltage circuits, a metal object can short circuit two terminals. Don't bypass safety devices. Three-wire mains outlets are designed to ground equipment to make it safe. If a live wire shorts to a grounded frame, the only result is an open fuse. If a live wire shorts to an ungrounded frame, the frame itself becomes hot and potentially dangerous. A fuse is a weak link in a circuit, designed to break down before anything else does. The maximum safe current in a circuit is determined by the designers. Too large a fuse can pass excessive current, damaging expensive equipment. Interlock switches are designed to remove power from a circuit when an access door, cover or panel is opened. When such a switch is "cheated" or otherwise disabled, a safety device has been bypassed. If you bypass an interlock for service or diagnostic purposes, use extreme caution. If you use air pressure to clean a machine, use low pressure (30 psi or less) and use eye protection (goggles or face masks). When using solvents or cleaning fluids, make sure ventilation is adequate.
WARNING!
Always be sure the SI1000 is unplugged before you make any attempt to perform the maintenance outlined in this manual.
1-3
1. Introduction
1.6 EQUIPMENT SAFETY
SI 1000
Just by walking around, you yourself may carry a threat to the equipment, in the form of a highvoltage electrostatic charge. Your body acts as a giant capacitor which can store large amounts of electricity. Walking across a rug can charge you with several thousand volts, which can discharge in a spark up to an inch long. Digital equipment can be easily damaged or destroyed by static charges. Microprocessors and other ICs contain tiny transistors not much more than a millionth of an inch across, which operate at 5 to 12 volts. You don't have to see a spark to ruin an IC -- 50 volts is enough. Follow these guidelines to protect sensitive equipment from static damage: Ground yourself before reaching into the equipment, or touching any circuit board or other electrical component. Just touching a doorknob or metal workbench may be enough, but the best guarantee is to turn the machine off but leave it plugged in, and ground yourself on the power supply metal casing, which is grounded through the three-wire power cord. If you have access to one, bring a grounding strap and use it. Be careful of rugs -- even a few steps can recharge you. Re-ground yourself whenever you've walked away and returned to the machine. Rugs are a major source of static buildup in the body. Take greater precautions as the objects you handle get smaller. A board in the machine is better protected than one which is not plugged in; a chip on a board is better protected than one in your hand. Stay away from metal conductors. The plastic and resin that chips and boards are made of are much better insulators than metal. It's most important to keep your hands away from any metal which contacts the data. In particular, this means the long connector along the bottom of each board, and the pins coming out of the chips. These signal and data lines are directly connected to the fragile inner circuits of the chips. When handling a board, try not to touch the connector; when handling a chip, try not to touch the pins.
1-4
OfficeRightTM Mailer SECTION 2.0 SPECIFICATIONS
2. Specifications
2.1
MATERIAL SPECIFICATIONS Sheets (Sheet Feeders A1 and/or A2)
EAME/International: USA/Canada: and Paper weight range: Sheet Feeder(s) capacity: 210mm Width 81/2" Width 81/2" Width x x x 297mm Length 11" Length 14" Length (DIN A4) (Letter) (Legal)
75g/m2 to 90g/m2 (20lbs to 24lbs) Up to 80 sheets of 80g/m2 (21lbs) paper can be loaded
Notes: Above materials from normal cut sheet or recycled stock capable of being processed through printers or photocopiers. If the materials are being processed through printers or photocopiers they do not have to be cooled first. The use of NCR, Lithographic/inkjet coated papers or glossy material is not recommended. The paper should be as flat as possible: When placed on a flat surface in either orientation, no part of the sheet shall be curled greater than 35mm (3/8") from the surface.
Fold Configuration
EAME/International: USA/Canada: Letter Size Legal Size C (standard) fold C (standard) fold double fold
Pack thickness (Manual Feeder M)
EAME/International: USA/Canada: Letter Size Legal Size Maximum of 3 sheets or 240g/m2 Maximum of 3 sheets Maximum of 2 sheets
Notes: Stapled or unstapled sets can be run. Unstapled sets are more prone to user error and misalignment. Feeders A1 and A2 cannot be used in conjunction with the Manual Feeder (M). The use of NCR, Lithographic/inkjet coated papers or glossy material is not recommended.
2-1
2. Specifications
Envelopes (Envelope Feeder B)
EAME/International: DL Mailer Width: Depth: 225mm to 235mm 110mm to 121mm
SI 1000
USA/Canada:
#10 Envelope Width: 91/2" Depth: 41/8" 70g/m2 to 100g/m2 (19lbs to 26lbs)
WIDTH
Envelope weight range: Envelope Feeder capacity: Envelope Flap Length:
Up to 60 off 90g/m2 (24lbs) Envelopes can be loaded Maximum: Minimum: Executive Flap (Triangular) 57mm (21/4") Parallel Flap 46mm (13/4") 32mm (11/4")
Throat Dimensions:
Minimum Throat Depth 6mm (1/4") Maximum Throat Depth 24mm (1") Place the envelope, closed flap down on a flat surface. Without applying any pressure to the envelope. The zone 30mm (11/8") either side of the centre-line of the envelope at the lead and trail edges, should not exceed 7mm (1/4") from the surface. No corner of the envelope should exceed 13mm (1/2") from the surface. End clearance between the insert and envelope is a minimum of 6mm (1/4") at each side i.e. a minimum of 12mm (1/2") overall. This measurement should be taken with all inserts placed into the envelope. The minimum clearance required for the envelopes and inserts from the top of a fully inserted package to the envelope flap crease is as follows: · Folded documents including inserts 6mm (1/4"). · Single sheet unfolded documents 3mm (1/8").
Curl or Twist Permitted:
End Clearance:
Depth Clearance:
Notes: Good quality recycled material can be used.
USA and Canada: The SI 1000 can accept a number 9 envelope into a number 10.
2-2
DEPTH
SI 1000 Inserts (Insert Feeder C)
Size: Maximum Width Maximum Depth Minimum Width Minimum Depth
2. Specifications
225mm (87/8") 114mm (41/2") 127mm (5") 86mm (33/8")
Material Weight: Insert Feeder Capacity:
Folded document: 70g/m2 to 90g/m2 (19lbs to 24lbs) Unfolded document: 70g/m2 to 200g/m2 (19lbs to 53lbs) 2 Up to 60 off 90g/m (24lbs) Business Reply Envelopes (BRE) can be loaded.
Notes: BRE's, Half folded and tri-folded documents must be presented to the SI 1000 with the closed (folded) edge forward only. The SI 1000 cannot run accordion folded documents.
Sealer
The machine can seal up to a maximum of 1,000 envelopes between refills.
Stacker
Stacker capacity is up to 60 filled envelopes, depending on contents of envelope.
Material Requirements
Materials should be good quality and properly stored. Recommended storage conditions: 18°C to 25°C 40% to 60% relative humidity
Double Detection
· The double detection is has been designed to detect the difference between 1 and multiple sheets/ inserts that have been fed from any of the SI 1000 feeders. Due to technology constraints, it is recommend you turn off the double detection when running BRE's.
·
2-3
2. Specifications
2.2 MACHINE SPECIFICATIONS Physical Dimensions
Width: Depth: Height: Weight: 440mm (173/8") 530mm (207/8") 365mm (143/8") without optional sheet feeder 2 400mm (153/4") with optional sheet feeder 2 17kg (371/2 lbs)
SI 1000
Noise Level
Running: <60dBA
Electrical
220- 240VAC, 50Hz, 1A 110VAC, 60Hz, 2.4A
Speed
Up to 900 cycles per hour (depending on fold and paper quality)
Duty Cycle
Up to a maximum of 2,000 cycles per month
Compliance:
Secap USA certifies that the SI 1000 series complies with the requirements of the Low Voltage Directive 73/23/EEC and the EMC Directive 89/ 336/EEC. The products were tested in a typical configuration.
ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTIFICATION AND ARE SUBJECT TO TEST.
2-4
OfficeRightTM Mailer 3. Theory of Operation SECTION 3.0 THEORY OF OPERATION 3.1 INTRODUCTION
The SI 1000 is a low volume automated folding and inserting machine. It is designed to handle repetitive mailing of, typically, 200 to 2000 documents per month. It is a small self-installable product, easy to use with a low level of noise similar to some laser printers. SI 1000 is available in 3 different configurations with an optional self-install second sheet feeder. All sheet feeder side guides are fixed at widths to accept either European DIN A4 or US letter/legal paper widths. The width of the sheet feeder supplied with the machine is dependent on the market it is sold to. Separating paper in the sheet feeder tray is done automatically by the use of a lift plate and drive roller. The envelope and insert feeder both have self centring guides and automatic separation for the different types of envelopes, business reply envelopes, compliment slips and tri-folded documents. For the customer, the separation of these materials is automatic, however, there is a service adjustment available if necessary. The envelope feeder will accept DL mailers or US No.10 envelopes. For countries taking the US PCN's, the customer will have an option to select either 11" or 14" paper lengths. The SI 1000 software will automatically adjust the timings to ensure the correct fold panel lengths are set. For DIN A4 and 11" paper the software will C-fold the paper, for 14" paper the software will adjust the timing so that a double fold is achieved, thus ensuring the complete package can be fully inserted into the envelope. On power-up, the cam is initialised by turning to its home position. If already in the home position the cam is reversed (anticlockwise) and then driven forwards (clockwise) to re-home and ensure it's always starting from the same position. This happens in all modes. Note: The length of an envelope is calculated by the lead edge blocking and then the trail edge clearing S12. To avoid stream feeding, on a trial piece after a preset count, a signal will be sent to stop the envelope feed motor M07. On a run cycle, the signal to stop envelope feed motor M07 is calculated from the length of the envelope that has been measured on the trial piece by the lead edge of the envelope on the run cycle triggering S12. This calculated length is also used on run cycles to detect variations in envelope length. After the trail edge has cleared S12 the exit motor M08 is stopped and then, after a short delay, reversed, so the envelope is diverted into the flapping chamber by a predetermined number of counts. This count ensures that any envelope within the specifications will be flapped successfully. This is the same in all modes that use an envelope.
3-1
3. Theory of Operation
Cam Position 1 Cam Position 2
SI 1000
Cam Position 3
Cam Position 4
Cam Position 5
Main Cam Positions
3.2
SINGLE SHEET FROM SHEET FEEDER A1 INTO AN ENVELOPE
When the customer presses Trial Piece, the cam turns anticlockwise from the home position to where the sheet feeder lift plate is in the raised position, to feed a sheet to the lead edge/DDD sensor S02 (see 'Cam Position 1'). At this stage, the envelope feed motor M07 drives an envelope through the separator stone and into the nip of the flapper and idler rollers, tripping S12. The exit motor M08 is started at the same time as the envelope motor. The flapping process (see note in section 3.1) will take place. As the lead edge of the envelope triggers S12, the sheet feeder will start to feed material via M01. The sheet will feed to the DDD sensor S02. On a trial piece, the DDD is calibrated for run cycles. On
3-2
SI 1000
3. Theory of Operation
run cycles, the machine will stop and display the appropriate message and action if multiple sheets are fed or no sheet reaches S02. If a single sheet is fed, it continues up to the collation sensor S01, into the bite of the collation nip rollers and then stops. M03 is started and 50ms later the cam turns clockwise, back to the home position (see 'Cam Position 2') to lower the lift-plate from the sheet feeder. Also, the sheet feeder motor M01 is stopped when the cam reaches the home position. The exit motor M08 then drives forward to flap the envelope and drives it on to the throating position defined by the envelope insert position count (adjustable in the service menu) where it stops. The cam is then turned clockwise to bring the insertion fingers into the envelope throat and drop the moistener nip rollers (see 'Cam Position 3'). The sheet is then driven up into the intelligent nip motor M04, until it blocks the intelligent nip sensor S06. The intelligent nip motor M04 will then run for a number of counts before stopping. This number of counts is determined by the machine PCN (letter or legal size for the U.S. and A4 for EAME). Also, the software will look at the setting that is selected in the 'move address in window position' adjustment. There is also an engineer-offset adjustment in the service menus that will change this value if the address cannot be moved into the window via the customer menu settings. When the count has been reached, the intelligent nip motor M04 stops and then reverses. This forces the paper to buckle into the nip of the fold rollers and creates the first fold. The paper then moves into the second buckle chute and blocks S07 (this is only present on machine configurations with an insert station fitted) and hits the fold plate. This will cause the paper to buckle and pass into the second nip of the fold rollers to create the second fold. The package is then driven through to the insertion sensor S08. When blocked, the insertion solenoid SOL2 is energised to bring the insertion rollers into the up position. This provides drive for the package to be inserted into the waiting envelope. When the package has been fully inserted into the envelope the main cam turns clockwise to retract the insertion fingers and brings up the moistener nip rollers (see 'Cam Position 4'). The main motor M03 is stopped and the insertion solenoid SOL2 is de-energised to drop the insertion rollers. The exit motor M08 is then driven a number of counts until the envelope reaches the seal position (this is where the envelope is required to be induced into the sealer rollers), where it stops. As M08 starts, if the seal function is selected, the software will count and set for the wetting constant. When this count is reached, the moistener solenoid SOL1 is energised and the moistener pressure bar is dropped down to wet the envelope flap. There is an option in the service menu to change the wetting constant. In addition, when M08 starts, it also counts for the inducer. When that count is reached, the cam is then turned clockwise to bring the inducer into the up position (see 'Cam Position 5'). The exit motor M08 restarts and drives for a number of counts and stops again. This movement forces the crease line of the flap through the sealer rollers to close the flap against the body of the envelope. The cam is then turned clockwise to lower the inducer. This also raises the sheet feeder lift plate. The cam is now back in the position as shown in 'Cam Position 1'. There are adjustments in the service menu to change the inducer timing. One adjustment sets the timing for the inducer to rise and guide the crease line into the sealer rollers (seal pos) and the second sets the timing for it to drop out of the way (pre seal counts). The exit motor M08 then drives the mail piece to the exit sensor S09. The mail piece is driven out of the top of the machine and onto the stacker. In run mode, the next cycle is started after a delay of 260ms. On a trial piece, the cam turns clockwise to its home position and the machine returns to the ready screen.
3-3
3. Theory of Operation
3.3 SINGLE SHEET FROM SHEET FEEDER A2 INTO AN ENVELOPE
SI 1000
On a trial piece or startup, the cam in sheet feeder A2 turns clockwise to raise the lift plate in the second sheet feeder. The main cam will not move anticlockwise round to Cam Position 1, it will stay in its home position and move from there. This is because there is no need to raise the lift plate in sheet feeder A1. At this stage, the envelope feed motor M07 drives an envelope through the separator stone and into the nip of the flapper and idler rollers, tripping S12. The exit motor M08 is started at the same time as the envelope motor. The flapping process (see note in section 3.1) will take place. Sheet feeder A2 motor M02 will start. The cam will turn anticlockwise and drive a sheet of material up through DDD sensor S03. The DDD routine will start, after a short delay, on the lead edge being detected by S03. The lift plate then drops and the material will carry on to the collation nip sensor S01. After a fixed count, sheet feeder A2 motor MO2 will stop feeding, as the material is in the bite of the collation nip rollers and the main motor MO3 will start to take control of the material. The exit motor M08 then drives forward to flap the envelope and drives it on to the throating position defined by the envelope insert position count (adjustable in the service menu) where it stops. The cam is then turned clockwise to bring the insertion fingers into the envelope throat and drop the moistener nip rollers (see 'Cam Position 3'). The sheet is then driven up into the intelligent nip, motor M04, until it blocks the intelligent nip sensor S06. The intelligent nip motor M04 will then run for a number of counts before stopping. This number of counts is determined by the machine PCN (letter or legal size for the U.S. and A4 for EAME). Also, the software will look at the setting that is selected in the 'move address in window position' adjustment. There is also an engineer-offset adjustment in the service menus that will change this value if the address cannot be moved into the window via the customer menu settings. When the count has been reached, the intelligent nip motor M04 stops and then reverses. This forces the paper to buckle into the nip of the fold rollers and creates the first fold. The paper then moves into the second buckle chute and blocks S07 (this is only present on machine configurations with an insert station fitted) and hits the fold plate. This will cause the paper to buckle and pass into the second nip of the fold rollers to create the second fold. The package is then driven through to the insertion sensor S08. When blocked the insertion solenoid SOL2 is energised to bring the insertion rollers into the up position. This provides drive for the package to be inserted into the waiting envelope. When the package has been fully inserted into the envelope the main cam turns clockwise to retract the insertion fingers and brings up the moistener nip rollers (see 'Cam Position 4'). The main motor M03 is stopped and the insertion solenoid SOL2 is de-energised to drop the insertion rollers. The exit motor M08 is then driven a number of counts until it reaches the seal position, this is where the envelope is required to be induced into the sealer rollers, where it stops. As M08 starts, if seal function is selected the software will count and set for the wetting constant. When this count is reached the moistener solenoid SOL1 is energised and the moistener Pressure bar is dropped down to wet the flap. There is an option in the service menu to change the wetting constant When M08 starts it also counts for the inducer. When that count is reached the cam is then turned clockwise to bring the inducer into the up position (see 'Cam Position 5').
3-4
SI 1000
3. Theory of Operation
The exit motor M08 restarts and drives for a number of counts and stops again. This movement has forced the crease line of the flap through the sealer rollers to close the flap against the body of the envelope. The cam is then turned clockwise to lower the inducer. This also raises the sheet feeder lift plate. The cam is now back in the position as shown in 'Cam Position 1'. There are adjustments in the service menu to change the inducer timing. One adjustment sets the timing for the inducer to rise and guide the crease line into the sealer rollers (seal pos) and the second sets the timing for it to drop out of the way (pre seal counts). The exit motor M08 then drives the mail piece to the exit sensor S09. The mail piece is driven out of the top of the machine and onto the stacker. In run mode, the next cycle is started after a delay of 260ms. On a trial piece, the cam turns clockwise to its home position and the machine returns to the ready screen.
3.4
TWO SHEETS FROM SHEET FEEDER A1 AND A2 INTO AN ENVELOPE
When the customer presses Trial Piece, the cam turns anticlockwise from the home position to where the sheet feeder lift plate is in the raised position, to feed a sheet to the DDD sensor S02 (see 'Cam Position 1'). Also, the cam in Sheet Feeder A2 turns clockwise to raise the lift plate in the second sheet feeder before feeding commences. At this stage the envelope feed motor M07 drives an envelope through the separator stone and into the nip of the flapper and idler rollers, tripping S12. The exit motor M08 is started at the same time as the envelope motor. The flapping process (see note in section 3.1) will take place. As the lead edge of the envelope triggers S12 the sheet feeder will start to feed material via M01. M02 will start to feed once the material from sheet feeder 1 has made the DDD sensor. The DDD routine will then start. If S03 is blocked then the machine knows that the second sheet has been fed. It will drive the material up. After a delay the software will look and see if the sheet from feeder 1 has finished feeding. If it has not, the sheet from feeder 2 will stop about 25mm from S01 and wait. This is to allow the sheet from sheet feeder 1 to reach S01. When S01 has been reached by the sheet from sheet feeder 1 M01 will drive it onward by a set amount of counts so it forms a buckle on the lead edge into the bite of the collation nip rollers. The second sheet will carry on and join it. On run cycles the machine will stop and display the appropriate message and action if multiple sheets are fed as the lead edge of the material triggers the sensors S02/S03 and the DDD routine has finished. If a single sheet is fed from each feeder they will continue up to the collation sensor S01 and stop. M03 is started and 50ms later the cam turns clockwise, back to the home position (see 'Cam Position 2') to lower the lift-plate from sheet feeder A1. Also the sheet feeder motor M01 is stopped when the cam reaches the home position. The lift plate for Sheet Feeder A2 will drop out of the way automatically as M02 turns the cam during feeding. The exit motor M08 then drives forward to flap the envelope and drives it on to the throating position defined by the envelope insert position count (adjustable in the service menu) where it stops. The cam is then turned clockwise to bring the insertion fingers into the envelope throat and drop the moistener nip rollers (see 'Cam Position 3').
3-5
3. Theory of Operation
SI 1000
The sheet is then driven up into the intelligent nip, motor M04, until it blocks the intelligent nip sensor S06. The intelligent nip motor M04 will then run for a number of counts before stopping. This number of counts is determined by the machine PCN (letter or legal size for the U.S. and A4 for EAME). Also, the software will look at the setting that is selected in the 'move address in window position' adjustment. There is also an engineer-offset adjustment in the service menus that will change this value if the address cannot be moved into the window via the customer menu settings. When the count has been reached, the intelligent nip motor M04 stops and then reverses. This forces the paper to buckle into the nip of the fold rollers and creates the first fold. The paper moves on into the second buckle chute and blocks S07 (this is only present on machine configurations with an insert station fitted) and hits the fold plate. This will cause the paper to buckle and pass into the second nip of the fold rollers to create the second fold. The package is then driven through to the insertion sensor S08. When blocked the insertion solenoid SOL2 is energised to bring the insertion rollers into the up position. This provides drive for the package to be inserted into the waiting envelope. When the package has been fully inserted into the envelope the cam turns clockwise to retract the insertion fingers and brings up the moistener nip rollers (see 'Cam Position 4'). The main motor M03 is stopped and the insertion solenoid SOL2 is de-energised to drop the insertion rollers. The exit motor M08 is then driven a number of counts until it reaches the seal position, this is where the envelope is required to be induced into the sealer rollers, where it stops. When M08 starts, if the seal function is selected, the software will count and set for the wetting constant. There is an option in service menu to change the wetting constant. When this count is reached the moistener solenoid SOL1 is energised and the moistener pressure bar is dropped down to wet the flap. The cam is then turned clockwise to bring the inducer into the up position (see 'Cam Position 5'). The exit motor M08 restarts and drives for a number of counts and stops again. This movement has forced the crease line of the flap through the sealer rollers to close the flap against the body of the envelope. The cam is then turned clockwise to lower the inducer (see 'Cam Position 5'). This also raises the sheet feeder lift plate. The cam is now back in the position as shown in 'Cam Position 1'. There are adjustments in the service menu to change the inducer timing. One adjustment sets the timing for the inducer to rise and guide the crease line into the sealer rollers (seal pos) and the second sets the timing for it to drop out of the way (pre seal counts). The exit motor M08 then drives the mail piece to the exit sensor S09. The mail piece is driven out of the top of the machine and onto the stacker. In run mode, the next cycle is started after a delay of 260ms. On a trial piece, the cam turns clockwise to its home position and the machine returns to the ready screen.
3.5
TWO SHEETS FROM SHEET FEEDER A2 (ACCUMULATION) INTO AN ENVELOPE
On a trial piece or startup, the cam in sheet feeder 2 turns clockwise to raise the lift plate in the second sheet feeder A2. The main cam will not move anticlockwise round to Cam Position 1, it will stay in its home position and move from there. This is because there is no need to raise the lift plate in sheet feeder A1. At this stage, the envelope feed motor M07 drives an envelope through the separator stone and into the nip of the flapper and idler rollers, tripping S12. The exit motor M08 is started at the same time as the envelope motor. The flapping process (see note in section 3.1) will take place.
3-6
SI 1000
3. Theory of Operation
The exit motor M08 then drives forward to flap the envelope and drives it on to the throating position defined by the envelope insert position count (adjustable in the service menu) where it stops. The cam is then turned clockwise to bring the insertion fingers into the envelope throat and drop the moistener nip rollers (see 'Cam Position 3'). Sheet feeder A2 motor M02 will feed a sheet of material up through DDD sensor S03. The DDD routine will start, after a short delay, on the lead edge being detected by S03. The lift plate will then drop and the material will carry on to the collation nip sensor S01. After a fixed count, sheet feeder A2 motor MO2 will stop feeding as the material is in the bite of the collation nip rollers and the main motor MO3 will start to take control of the material. The material will then travel up towards the intelligent nip. After a 240ms delay the intelligent nip motor M04 will start. When the trail edge of the material clears the collation sensor S01 the main motor M03 will drive a fixed count and then both M03 and M04 will reverse. When the material blocks S01 the sheet feeder A1 motor M01 will drive in reverse as well. At this point, the material is diverted towards the front of the machine via the gate just before S01. When the material clears S06 there is a delay of 180ms and M04 will stop. Once S01 has cleared, the main drive motor M03 and M01 will stop. This will hold the material in place just below the convenience feeder. There will be a delay of 50ms, then M01 will drive forward until S01 is made. Once this happens, M01 will drive the material into the nip of the collation rollers, stop and hold. Sheet feeder A2 motor M02 will start. The cam will raise the lift plate for drive and feed a sheet of material up through DDD sensor S03. The DDD routine will start after a short delay on the lead edge being detected by S03. The lift plate will then drop and the material will carry on to the collation nip sensor S01. When it reaches this position, M01 and M03 are started. This drives all the staged sheets into and through the collation nip rollers. The sheets are then driven up into the intelligent nip, motor M04, until they block the intelligent nip sensor S06. The intelligent nip motor M04 will then run for a number of counts before stopping. This number of counts is determined by the machine PCN (letter or legal size for the U.S. and A4 for EAME). Also, the software will look at the setting that is selected in the 'move address in window position' adjustment. There is also an engineer-offset adjustment in the service menus that will change this value if the address cannot be moved into the window via the customer menu settings. When the count has been reached the intelligent nip, motor M04 stops and then reverses. This forces the paper to buckle into the nip of the fold rollers and creates the first fold. The paper moves on into the second buckle chute and blocks S07 (this is only present on machine configurations with an insert station fitted) and hits the fold plate. This will cause the paper to buckle and pass into the second nip of the fold rollers to create the second fold. The package is then driven through to the insertion sensor S08. When blocked the insertion solenoid SOL2 is energised to bring the insertion rollers into the up position. This provides drive for the package to be inserted into the waiting envelope. When the package has been fully inserted into the envelope the cam turns clockwise to retract the insertion fingers and brings up the moistener nip rollers (see 'Cam Position 4'). The main motor M03 is stopped and the insertion solenoid SOL2 is de-energised to drop the insertion rollers. The exit motor M08 is then driven a number of counts until it reaches the seal position, this is where the envelope is required to be induced into the sealer rollers, where it stops. When M08 starts, if the seal function is selected, the software will count and set for the wetting constant. There is an option in service menu to change the wetting constant. When this count is reached the moistener solenoid SOL1 is energised and the moistener pressure bar is dropped down to wet the flap. The cam is then turned clockwise to bring the inducer into the up position (see 'Cam Position 5').
3-7
3. Theory of Operation
SI 1000
The exit motor M08 restarts and drives for a number of counts and stops again. This movement has forced the crease line of the flap through the sealer rollers to close the flap against the body of the envelope. The cam is then turned clockwise to lower the inducer (see 'Cam Position 6'). This also raises the sheet feeder lift plate. The cam is now back in the position as shown in 'Cam Position 1'. There are adjustments in the service menu to change the inducer timing. One adjustment sets the timing for the inducer to rise and guide the crease line into the sealer rollers (seal pos) and the second sets the timing for it to drop out of the way (pre seal counts). The exit motor M08 then drives the mail piece to the exit sensor S09. The mail piece is driven out of the top of the machine and onto the stacker. In run mode, the next cycle is started after a delay of 260ms. On a trial piece, the cam turns clockwise to its home position and the machine returns to the ready screen.
3.6
JOBS THAT RUN AN INSERT
All jobs will run as previously stated above, with the addition of the following routine: When the sheet feeder motors stop feeding, M06A and M06B will feed an insert up to S10. When the collation reaches S07, the software will then look at the nesting constant. When that count is reached M06B will fire the insert into the collation. M06A will also drive for a fixed insert exit count. There is an adjustment in the service menu where the firing constant can be changed to ensure the insert sits snugly into the collation. As the material is fired, the software will look at the DDD. If no DDD was found then M06B will stop driving after S10 is cleared. If the job to be run is 'insert only', the insert routine will start when S12 is triggered by the lead edge of the envelope.
3.7
FOLD ONLY
If 'fold only' is selected, the machine will run as normal but without the envelope routine. This means that the cam will miss out 'Cam Position 3' and skip round to 'Cam Position 4'. Also, the sealer solenoid will not be in operation.
3-8
OfficeRightTM Mailer 4. Removal & Replacement SECTION 4.0 REMOVAL & REPLACEMENT
IMPORTANT NOTE: Most covers on the SI 1000 are located using plastic clips and latches. If a clip or latch is broken, many covers have the ability to be secured using screws instead. This manual assumes all covers are `as new' and located using the original devices.
4.1
RIGHT HAND SIDE COVER
WARNING: Disconnect power from the machine before attempting to remove the covers. 1. 2. 3. Open front cover 'D' and insert cover 'E'. Remove the water tank. Remove the cover securing screw located at the grab handle.
4.
Remove the cover by easing the locating tabs from the side frame at the top, rear and lower left edge. The cover can then be lifted from the bottom. Reassemble in reverse order.
5.
4.2
LEFT HAND SIDE COVER
IMPORTANT: The left cover is removed in a similar way to the right hand cover detailed above. 1. 2. 3. 4. Open front cover 'D' and insert cover 'E'. Remove the cover securing screw located at the grab handle. Remove the cover by easing the locating tabs from the side frame at the top, left and right edge. The cover can then be lifted from the bottom. Reassemble in reverse order.
4-1
4. Removal & Replacement
4.3 EXIT IDLER ASSEMBLY
1. Ease the exit idler assembly forwards until the two plastic latches release, then pull the assembly directly upwards to disengage the pivots. Remove the two retaining springs, noting the colour and orientation of each spring for reassembly.
SI 1000
2.
3.
To reassemble: · If the inducer assembly incorporates two coil springs, remove them before refitting the exit idler assembly. Once the assembly is refitted, open cover D and relocate the two coil springs from underneath. · Locate the exit idler assembly retaining springs into position. · Introduce the assembly from above, putting tension into the springs and push down to locate the pivots. · Let the cover assembly under spring pressure, engaging the two plastic latches as it does.
4.4
STACKER COVER
1. 2. 3. Remove the stacker tray and the exit idler assembly (see section 4.3 above). Open the top cover 'D'. Release the two retaining clips (A), one on each side. Use a flat blade screwdriver in the aperture shown and push each clip towards the front of the machine.
A
3.
Taking care not to damage the exit switch, tilt the cover forwards until it is released from its locating studs. Reassemble in reverse order.
4.
4-2
SI 1000 4.5
4. Removal & Replacement
ENVELOPE FEEDER COVER
1. 2. Open the top cover 'D' and insert cover 'E'. Release the two retaining clips (A), one on each side. Use a screwdriver in the aperture shown and push each clip inwards to release the cover.
A
3. 4.
Lift the cover from the machine. Reassemble in reverse order, making sure that the lip on the front of the cover is located UNDER the exit are cover.
4.6
CONTROL PANEL (USER INTERFACE)
1. 2. 3. Remove the right hand cover (see section 4.1). Unlatch the top of the control panel and rotate forwards approximately 90°, then release the panel from the frame. Carefully disconnect the harness. Reassemble in reverse order.
4.7
REAR COVER
1. 2. 3. Open the insert cover 'E'. Release the four retaining clips (A) (2 each side) and screws (if fitted) and remove cover. Reassemble in reverse order, making sure the ribbon cable from the rear distribution board is curled upwards inside the cover.
A
4-3
4. Removal & Replacement
4.8 TOP COVER
1. 2. 2. Remove the rear cover (see section 4.7 above). Release the four retaining clips (2 each side) and rotate cover backwards and out of the machine. Reassemble in reverse order.
SI 1000
4.9
INSERT FEEDER ASSEMBLY
1. 2. 3. Remove the rear cover (see section 4.7). Disconnect the ribbon cable from P1B on the rear distribution board. Gently prise the two stays from the side frames.
Stay location
4.
Pivot the insert feeder assembly towards the back of the machine and carefully lift the assembly out of the machine. Reassemble in reverse order.
5.
4-4
SI 1000 4.10
4. Removal & Replacement
ENVELOPE FEEDER/EXIT ASSEMBLY
1. 2. Remove the right and left hand covers (see sections 4.1 and 4.2). Disconnect connector PL4 located on the right hand side frame of the machine.
Connector PL4
3. 4.
Gently prise the two stays from the side frames. Remove the E clips and carefully disconnect the Gas Struts. WARNING: The envelope feeder/exit assembly is quite heavy and is now unsupported by the gas struts. Take care not to trap your fingers.
Prise off stays
5.
Pivot the assembly towards the back of the machine until the flats on the pivot studs aline with the gaps in the side frames, then carefully lift the assembly upwards out of the machine. Reassemble in reverse order.
Disconnect gas struts
6.
4.11
SHEET FEEDER ASSEMBLY
1. 2. Remove by gently sliding the assembly out of the front of the machine. Reassemble in reverse order. IMPORTANT: When reassembling, make sure the lift cam is in the lower position.
4.12
INDUCER COVER
1. 2. 3. Open front cover D and remove the sheet feeder assembly (see section 4.11 above). Release the retaining clips (A) on the outer sides of the cover. Pivot the cover forwards to remove. Reassemble in reverse order. Engage the lower locating tabs first, then pivot the cover up and latch it into position.
A
4-5
4. Removal & Replacement
4.13 INDUCER ASSEMBLY
SI 1000
IMPORTANT: There are two styles of inducer assembly which can be fitted to the SI 1000. The illustrations in this section show the more complicated assembly. Any differences in procedure for the simpler assembly are given in the text. 1. 2. Remove the left cover (see section 4.2) and the inducer cover (see section 4.13). CAREFULLY flex the actuator arm outwards JUST ENOUGH to release the inducer crank shaft . CAUTION: Flexing the actuator arm too much could cause breakage - take care. Also, check that the actuator arm does not come unlatched from its pivot shaft.
Disengage crank shaft from actuator arm
3.
Rotate the inducer assembly (A) away from you. Some inducers incorporate a lower beam. If fitted, the flats on the lower beam (B) will align with the gaps in its pivots and the beam will disengage from the pivots. CAUTION: Take care not to damage the front interlock sensor.
B
A
4. 5.
Some inducers incorporate idler rollers (C). If fitted, depress them and hold them down. Grasp the inducer assembly, rotate it vertically, push to the left to disengage it from the right side frame and lift it clear of the machine.
Rotate and push left to disengage
C
6.
Reassemble in reverse order. On inducers fitted with a lower beam, you will need to manually rotate the beam forwards before relocating the crank shaft into its actuator arm.
4-6
SI 1000 4.14 POWER SUPPLY BOARD
1.
4. Removal & Replacement
Remove the two screws (A) securing the power supply unit plastic cover and remove the cover.
A
2. 3. 4.
Remove three screws (B) securing the power supply. Ease out the power supply and disconnect plug P8 on the circuit board. Reassemble in reverse order.
B
4.15
DISCONNECTING THE UPPER AND LOWER FRAMES
1. Remove: Left cover (see section 4.1). Right cover (see section 4.1). Rear cover (see section 4.7). The sheet feeder assembly (see section 4.11). The inducer cover (see section 4.12). The power supply (see section 4.14). 2. Disconnect the following plugs and leads from the main board: P1, P2 (ribbon cable), P6, P13, P14, P18, and earthing (ground) tag 21. 3. 4. Remove the four retaining clips and carefully lift the upper frame off. Reassemble in reverse order.
4-7
4. Removal & Replacement
4.16 ENVELOPE SEPARATOR STONE ASSEMBLY (RETARD PAD ASSEMBLY)
1. 2. 3. Remove the envelope feeder cover (see section 4.5) and the stacker cover (see section 4.4). Remove the belt (A) from the pulley on the right hand side of the machine. Remove two screws (B) and move motor (C) aside.
SI 1000
C
B A
4. 5.
Remove the belt (D) from the pulley on the left hand side of the machine. Remove two screws (E) and move exit motor (F) aside.
E
F
D
6.
Remove the four screws (G) that locate the envelope separator assembly in place, and lift the assembly from the machine. NOTE: USA and Canadian models incorporate 'jockey' rollers that rotate against the outer envelope feed belts. This makes no difference to the removal procedure.
G
7. 8.
Using a spring hook, unhook the two springs to release the retard pad from the envelope separator assembly. Reassemble in reverse order. IMPORTANT: When refitting the exit motor (F), Adjust the motor position to tension belt (D) sufficiently to prevent jumping.
4-8
SI 1000 4.17
4. Removal & Replacement
SEPARATOR BELT CARRIERS
1. Remove the envelope feeder cover (see section 4.5) and the envelope feeder/exit assembly (see section 4.10). If you are replacing the centre separator belt carrier ONLY, also remove the envelope separator stone assembly (see section 4.16). Remove the two drive belts and pulley (A, B and C). Pull out the pulley and drive shaft (D) from the frame.
B C D
A
2.
3. 4.
5.
Unclip the belt carriers as required using a flat blade screwdriver. Reassemble in reverse order.
6.
4.18
EXIT ROLLER SHAFT AND EXIT SENSOR
1. 2. Remove the stacker cover (see section 4.4). Unlock both bearing latches (A): Lift each latch arm and rotate the arm until it aligns with the frame cutouts. Remove the exit roller shaft (B). At this point you can unclip the exit sensor (C). Be careful not to break the arm of the sensor. Reassemble in reverse order.
C A
B
A
3. 4. 5.
4-9
4. Removal & Replacement
4.19 SEALER IDLER ROLLER
1. 2. 3. Remove the stacker cover (see section 4.4). Remove latch spring (A). Remove both springs (B) from sealer idler roller.
A
SI 1000
B
4.
Gently prise the left hand latch arm (C) from the latch shaft. Rotate the shaft and pull it out of the machine to the right. Raise the roller (D) in its slot until the bearings align with the cutouts in the side frame, then push each bearing from the shaft. Reassemble in reverse order.
C
5.
D
6.
4.20
SEALER ROLLER
1. 2. Open front cover D. Remove drive belt (A).
A
C
3.
Unlock both bearing latches (B): Lift each latch arm and rotate the arm until it aligns with the frame cutouts. Remove the sealer roller (C). Reassemble in reverse order. IMPORTANT: The sealer roller is grey in colour. It should not be confused or swapped with the flapper roller which is black.
B
4. 5.
4-10
SI 1000 4.21
4. Removal & Replacement
MOISTENER DEFLECTOR ASSEMBLY
1. 2. Open front cover D. Depress both clips that latch the deflector using a flat blade screwdriver. There is one clip each side. Remove the deflector assembly. On reassembly, take care to locate the clips into their slots. Slight pressure is needed to depress the clips.
3. 4.
4.22
IDLER SUPPORT BAR
1. 2. 3. 4. Open top cover D. Unclip support bar assembly (A) from side frame. Idler rollers unclip from springs. Reassemble in reverse order.
A
4.23
FLAPPER ROLLER
1. 2. Remove the moistener deflector assembly (see section 4.21). Unlock both bearing latches (A): Lift each latch arm and rotate the arm until it aligns with the frame cutouts. Remove the flapper roller (B). Reassemble in reverse order. IMPORTANT: The flapper roller is black in colour. It should not be confused or swapped with the sealer roller which is grey.
B A
3. 4.
4-11
4. Removal & Replacement
4.24 FLAPPER ASSEMBLY
1. 2. Remove flapper roller (see section 4.23) and envelope feeder cover (see section 4.5). Disconnect P8 from the front frame distribution board and release the flapper sensor wiring from the routing 'hooks' below the board. Remove the two screws and locating plates (A) from the flapper assembly.
A
SI 1000
3.
4. 5. 6.
Depress the two tags (B) near each side frame and unclip the flapper assembly (C). The flapper fingers clip-in. To remove, unlatch and rotate. Reassemble in reverse order.
C B
4.25
IDLER SUPPORT FRAME ASSEMBLY
1. 2. Remove idler support bar (see section 4.23) and flapper assembly (see section 4.24). Rotate assembly until it releases from frame. CAUTION: Take care not to damage the idler support frame. You will feel some resistance from the orbital roller as the frame is rotated.
3. 4.
Idler rollers can be removed after first removing the retaining clip (A). Reassemble in reverse order.
A
4-12
SI 1000 4.26 ORBITAL ROLLER
1. 2. 3.
4. Removal & Replacement
Remove idler support frame (see section 4.25). Remove Springs (A) from each end of roller. Raise the roller in its slot until the bearings (B) align with the cutouts in the side frame, then push each bearing from the shaft. The orbital roller can now be removed from the machine. Reassemble in reverse order.
B A
4. 5.
4.27
INSERT FEEDER SEPARATOR BLOCK
1. 2. 3. 4. 5. 6. Remove the rear cover (see section 4.7). Disconnect P5 from the rear distribution board. Open rear cover E. Remove four screws (A) from housing assembly. Unhook the two springs (B) locating the separator block. Carefully lift off the housing assembly. You can now pull the separator block and springs from the housing assembly. Reassemble in reverse order.
A B A
7.
4.28
INSERT FEEDER BELT CARRIER ASSEMBLY AND TRANSPORT SHAFT
1. Remove the insert feeder separator block housing (see section 4.27), but leave the separator block itself in place in the housing. Remove the top cover (see section 4.8). Remove the belt (A) and pulley (B), then unlock the bearing and pull out shaft (C).
C B A
2. 3.
4-13
4. Removal & Replacement
4. 5. Lift off the insert feeder feed deck (D). The belt carrier assembly (E) can be removed after carefully unlatching it using a flat blade screwdriver through the access slot as shown. IMPORTANT: Take care not to damage the rear distribution board with the screwdriver. 6. The transport shaft (F) can be removed after removing its drive belt and unlocking its bearings.
SI 1000
D E
F
7.
Reassemble all components in reverse order. IMPORTANT: There is a one way clutch on the pulley removed in step 3 above. It spins freely in the anticlockwise direction. When refitting, check that it will drive the carrier belts in the correct direction.
4.29
MAIN CAM
1. 2. Remove left hand side cover (see section 4.2). Remove link (A) and disconnect spring (B).
B A
3.
CAREFULLY flex the inducer actuator arm outwards JUST ENOUGH to release it from the inducer crank shaft. CAUTION: Flexing the actuator arm too much could cause breakage - take care. Also, check that the actuator arm does not come unlatched from its pivot shaft.
4. 5.
Press the latch (C) and disconnect the linkage to the insertion fingers. Remove the main cam.
C
4-14
SI 1000 4.30 FOLD ROLLERS
1.
4. Removal & Replacement
D
Remove the envelope feeder/exit assembly (see section 4.10) and the main cam (see section 4.29). Remove idler gear (D) behind cam. Unscrew ESD tag (E) from cam side.
E
2. 3.
4.
Remove four gears (F) from right hand side of machine.
F
F
5. 6.
Remove Fold Roller springs (G) (two each side). To remove the spring loaded rollers (H), move the roller in its slot until the bearings align with the cutouts in the side frame, then push each bearing from the shaft. To remove the two rollers (I), unlock the roller bearings and pull off the bearings.
I
G H
7.
8.
Reassembly in reverse order, noting the following points: · The fold rollers should be reassembled with the WIDE slot on the shafts towards the LEFT hand (cam) side of the machine. · Fit the rollers and bearings before refitting the fold roller springs.
4-15
4. Removal & Replacement
4.31 FINGER FRAME
1. 2. 3. Disconnect the upper and lower frames (see section 4.15). Remove the main cam (see section 4.29). Disconnect the two springs (A) between the finger frame and the moistener frame.
A
SI 1000
4. 5.
Remove the screw (B) from the actuator (C) and pull the actuator from the finger frame. Remove the bearing (D). Lift the latch arm, rotate the arm until it aligns with the frame cutout and then pull the bearing from the finger frame. The frame can now be removed. Reassemble in reverse order.
C D B
6. 7.
4.32
MOISTENER NIP FRAME ASSEMBLY
1. 2. 3. Remove the finger frame (see section 4.31). Pull off the inducer actuator (A). Unlock the bearing (B). Rotate the bearing until it can be pulled from the moistener frame.
A
B
4.
Remove the bearing (C). Lift the latch arm, rotate the arm until it aligns with the frame cutout and then pull the bearing from the finger frame. The frame can now be removed. Reassemble in reverse order.
C
5. 6.
4-16
SI 1000 4.33
4. Removal & Replacement
INSERTION FRAME ASSEMBLY
1. 2. 3. 4. 5. Remove the moistener nip frame (see section 4.32). Disconnect the two springs (A) between the insertion frame and the upper frame. Disconnect the wiring to the insertion switch (B). Unscrew the two pivot screws (C) (one on each side). The frame can now be removed. As the frame is lifted clear, slide the solenoid actuator out of the solenoid body. Reassemble in reverse order.
A B
C
6.
4.34
CONVENIENCE FEEDER SHAFT
1. 2. 3. Disconnect the upper and lower frames (see section 4.15). Remove belt (A). Unlock both bearing latches (B): Lift each latch arm and rotate the arm until it aligns with the frame cutouts. Remove the convenience feeder shaft. Reassemble in reverse order.
B A
4. 5.
4.35
SHEET FEEDER A1 SHAFT
1. 2. 3. Disconnect the upper and lower frames (see section 4.15). Remove both belts (A). Unlock both bearing latches (B): Lift each latch arm and rotate the arm until it aligns with the frame cutouts. Remove the shaft through the frame towards the right hand side.. Reassembly in reverse order.
B A
4. 5.
4-17
4. Removal & Replacement
4.36 LIFT ARM AND GATE ASSEMBLY
1. 2. 3. 4. 5. 6. Disconnect spring (A). Unlock latch (B) and remove the lever assembly (C). Unlatch bearing (D) and remove bearing. Remove lift arm through the bottom of the frame. Push in tags (E) on upper side of Gate Assembly and slide the gate down to remove. Reassemble in reverse order.
C A B E
SI 1000
D
4.37
LOGIC BOARD
1. 2. 3. 4. Remove power supply board (see section 4.14). Disconnect all electrical connections from the logic board. Remove locating screw from board. Carefully pull the top edge of the board forward from the locating posts. CAUTION: You will need a tool such as a spring hook to pull the top edge of the board forwards. Take extreme care not to damage the board during this operation. 5. Reassemble in reverse order.
4.38
SHEET FEEDER A2 TOP METAL COVER
1. Remove the SI 100 from sheet feeder A2. CAUTION: Make sure the machine separates from the sheet feeder as it is lifted. 2. 4. Remove two locating screws (A). Slide the cover (B) to one side and lift clear. Disconnect P1 from sheet feeder 2 PCB if you need to completely remove the cover. Reassemble in reverse order.
B A
5.
4-18
SI 1000 4.39 SHEET FEEDER A2 PCB
1. 2. 4. 5.
4. Removal & Replacement
Remove the sheet feeder A2 top metal cover (see section 4.38). Disconnect connectors P1, P2, P3, P4 and P5 from the PCB. Unclip the PCB to remove it. Reassemble in reverse order.
P3 P1 P2, P4, P5
Paper sensor
4.40
SHEET FEEDER A2 PAPER SENSOR
1. 2. 3. 4. Remove the sheet feeder A2 top metal cover (see section 4.38). Disconnect connectors P2, and P5 from the PCB. Unclip the paper sensor to remove it. Reassemble in reverse order.
4.41
SHEET FEEDER A2 MAIN DRIVE MOTOR
1. 2. 3. 4. 5. 6. Remove the sheet feeder A2 top metal cover (see section 4.38). Unclip and remove sheet feeder 2 left and right hand plastic covers. Remove the two drive belts (A). Disconnect electrical connector from the motor. Remove two screws (B) and lift motor clear. Reassemble in reverse order.
A
B
4-19
4. Removal & Replacement
4.42 SHEET FEEDER A2 DRIVE SHAFT
1. Remove the sheet feeder A2 top metal cover (see section 4.38) and the paper sensor (see section 4.40). Unclip and remove sheet feeder 2 left and right hand plastic covers. Remove the drive belts (A) and (B). Unlock both bearing latches (C): Lift each latch arm and rotate the arm until it aligns with the frame cutouts. Remove the drive shaft (D). Reassemble in reverse order.
D C
SI 1000
A
2. 3. 4.
B
C
5. 6.
4.43
SHEET FEEDER A2 FEED SHAFT
1. Remove the SI 1000 from sheet feeder A2. CAUTION: Make sure the machine separates from the sheet feeder as it is lifted. 2. 3. Unclip and remove sheet feeder 2 left and right hand plastic covers. Unlock both bearing latches (A): Lift each latch arm and rotate the arm until it aligns with the frame cutouts. Remove the feed shaft (B). Reassemble in reverse order.
A B A
4. 5.
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OfficeRightTM Mailer SECTION 5.0 ADJUSTMENTS
5. Adjustments
IMPORTANT: All adjustments are factory set to nominal positions to allow repetitive feeding of in specification material. Therefore, adjusting these settin