GBR Systems Corporation 12 Inspiration Lane Chester, CT 06412-1366 Toll Free: 800-833-6167; Phone: 860-526-9561; Fax: 860-526-2747; E-mail: sales@gbr.com 420T V6LT OPERATOR & SERVICE MANUAL 071-33370-400 ISSUE 01/2010 Rev.
TABLE OF CONTENTS Feed Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Table of Contents Feed Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 SECTION A INTRODUCTION . . . . . . . . . . . . . . . . 10 Read Gate (Line Code Gate) Sensor . . . . . . . . . . . . . . . . . 15 A.1 INTRODUCTION TO THE MANUAL . . . . . . . . . . 10 Feed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 A.2 INTRODUCTION TO THE MACHINE. . . . . . . . . .
TABLE OF CONTENTS A.6a System Setup . . . . . . . . . . . . . . . . . . . . . . . 29 A.9 Setting the 420T to Read Laser Bar Code . . . . . . 54 A.6b Feeder Setup . . . . . . . . . . . . . . . . . . . . . . . 31 A.9a Adjusting the Paper Guides . . . . . . . . . . . . . . . 54 A.6c Accumulator Setup . . . . . . . . . . . . . . . . . . . . 32 Bar Read Setup 1 . . . . . . . . . . . . . . . . . . . . . . . . 55 A.6d Folder Setup (Future Option). . . . . . . . . . . . . . . 32 Bar Read Setup 2 . . . . . .
TABLE OF CONTENTS Addendum II. . . . . . . . . . . . . . . . . . . . . . . . . 65 C.2a Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 75 Signal Specification . . . . . . . . . . . . . . . . . . . . . . . 65 C.2b I/O Reference Tables 420T V6LT I/O Table 0 . . . . . . 76 1) RR Donnely 1 Protocol: . . . . . . . . . . . . . . . . . . . 65 C.2c I/O Reference Tables 420 V6LT I/O Table 1 . . . . . . . 77 2) RR Donnely 2 Protocol: . . . . . . . . . . . . . . . . . . . 66 C.
TABLE OF CONTENTS C.3d (12xxx) Feeder . . . . . . . . . . . . . . . . . . . . . . 83 15002 “Jam At In Sensor Error” . . . . . . . . . . . . . . . . . . . 89 12001 “No Feed Error” . . . . . . . . . . . . . . . . . . . . . . . . 83 15003 “Jam At Out Sensor Error” . . . . . . . . . . . . . . . . . . 90 12020 “DOUBLE PAGE FED” . . . . . . . . . . . . . . . . . . . . 84 15004 “Jam Into Transfer Conveyor” . . . . . . . . . . . . . . . . 90 12021 “Below Minimum Speed” . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS 15041 “False Feed Out Of Xfer Station 1”. . . . . . . . . . . . . . 96 nnn05 “DUPLICATE PAGE” . . . . . . . . . . . . . . . . . . . . 103 15042 "False Feed Into Xfer Station 2” . . . . . . . . . . . . . . . 97 nnn06 “PAGE OUT OF SEQUENCE” . . . . . . . . . . . . . . . 103 15042 “False Feed Into Xfer Station 2" . . . . . . . . . . . . . . . 97 15043 “False Feed Out Of Xfer Station 2”. . . . . . . . . . . . . . 97 nnn07 “INVALID GROUP” . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS nnn28 “UN-EXPECTED RESPONSE” . . . . . . . . . . . . . . . 105 nnn51 "SETUP TIMEOUT ERROR" . . . . . . . . . . . . . . . . 107 nnn29 “EXPECTED READING” . . . . . . . . . . . . . . . . . . 106 nnn52 "READLESS READ ERROR" . . . . . . . . . . . . . . . 107 nnn30 “READER REBOOTED” . . . . . . . . . . . . . . . . . . 106 nnn53 "CUSTOMER ID CHANGED IN SET" . . . . . . . . . . . 107 nnn31 “CALIBRATION IN RANGE” . . . . . . . . . . . . . . .
TABLE OF CONTENTS 420T/438 - Barcode Data Specification 3 - 2D - Rev.3 . . . . 113 D.3 Single Channel Read Card . . . . . . . . . . . . . . 126 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 D.3a Function: . . . . . . . . . . . . . . . . . . . . . . . . . 126 Bar Code Description . . . . . . . . . . . . . . . . . . . . . . . . 113 D.3b LED Indications: . . . . . . . . . . . . . . . . . . . . . 127 Bit Numbering per Character Conventions: . . . . . . . . . . . .
TABLE OF CONTENTS F.3 Read Zone Diagrams: . . . . . . . . . . . . . . . . 136 Insert Sta.:00: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 F.4 Engineering Values . . . . . . . . . . . . . . . . . . 137 Postal Meter Divert: . . . . . . . . . . . . . . . . . . . . . . . . . 141 F.5 Typical Postal Metering Setup Presets . . . . . . . 141 Test - “Setup”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Insert Sta.-:2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION While every care has been taken in the preparation of this manual, no liability will be accepted by GBR Systems Corporation arising out of any inaccuracies or omissions. All service documentation is supplied to GBR Systems Corporation external customers for informational purposes only. GBR Systems Corporation service documentation is intended for use by certified, product trained service personnel only. GBR Systems Corporation does not warrant or represent that such documentation is complete.
INTRODUCTION SECTION A INTRODUCTION A.1 INTRODUCTION TO THE MANUAL Creeper Conveyor This manual is intended for service technicians and is organized to enhance preventive maintenance, troubleshooting, and repair of the 420T. Installation of the 420T is also described. A.2 INTRODUCTION TO THE MACHINE A.2a FEEDER SECTION The 420T’s feeder is bottom fed, top loading for continuous operation, with a capacity of 1500 sheets (20 lb stock) using the GBR Systems Creeper Conveyor.
INTRODUCTION Hopper and Feeder Paper Guide Rails: The two stainless steel rails mounted on the sides of the creeper conveyor are adjustable via a locking handle at the rear. At the front they interlock with the feeder side rails, and lock to shafts running across the machine. Both sets of rails should be adjusted at the same time making sure there is only a slight angle toward the feeder paper hopper to guide the paper gently without pinching.
INTRODUCTION 420T Feeder Components 420T V6LT OPERATOR & SERVICE MANUAL 071-33370-400 ISSUE 2009/06 Rev.
INTRODUCTION Feed Belt Paper Level Detector The Main Feed Belt is a one inch wide tan timing belt which drives the bottom sheet of paper under the singulator roller. Also called Singulator Belt. Also known as the demand switch, monitors the paper going into the feeder area. It’s job is to limit and demand the amount of paper that is most productive to the feeding process. The Paper Level Detector monitors the paper through a metal wand.
INTRODUCTION Feeder Speed Encoder Dump Brake A blue-clad optical encoder located on the right side of the upper pullout shaft. It is used to detect feeder run speed. This prohibits the rollers from releasing paper from the accumulator. A.2c ACCUMULATOR SECTION Dump Clutch This activates the stacking rollers, releasing the accumulated pages. Right Side of Feeder The accumulator receives and holds paper coming from the feeder. It will stack groups from one to seven documents.
INTRODUCTION Feed Clutch An electrical clutch that engages the feed belt by a signal from the controller. Stream feeding is also the faster method of feeding with the shortest gap between the sheets. Read Gate (Line Code Gate) Sensor Feed Brake Feeder Sensors Thru beam sensor mounted within the brackets holding the F40 Reader. It tells the reader to begin looking for line code marks when the sensor sees the leading edge of the paper.
INTRODUCTION Double Detect Sensor The double detect sensor is an ultra sonic sensor that does not require electrical adjustment. The mechanical position of the sensor is 40mm above the mounting plate +/- 2mm. The distance and the alignment is critical. The sensor determines that two sheets have been fed by detecting an induced field between the two pages. the Dump Rollers into the folder. A maximum of 7 pages can be fed into the collected and fed into the folder.
INTRODUCTION Folder Rollers Adjusting The Folder Speed: Used to nip the paper as it is buckling, creating the fold. Although the folder speed has been set at the factory it may be necessary to Folder Drive Motor & Controller Board A 110VAC motor that is controlled by a circuit board to achieve a constant speed. The motor drives all folder roller shafts. Folder Drive Motor & Controller Board A 110VAC motor that is controlled by a circuit board to achieve a constant speed.
INTRODUCTION Folder Speed Encoders There are two folder speed encoders. The one seen in the picture below is used to report the folder speed to the operator/maintenance person through the monitor. The lower left picture is the other encoder used by the folder control board. Folder Motor Cover Removed Folder Left Side The pulses generated by the encoder Disc and Sensor, shown in the picture on the lower left of this page, are used by the motor control board to maintain a set speed.
INTRODUCTION A.2e Components of the Controller Box Inside The Computer Box DC Power Distribution Chassis: With cover removed you can see The DC Power Distribution Chassis, the Computer Chassis, Interlock Terminal Blocks, Fuses 1-3 and the Interlock Gate Monitoring Module. 420T V6LT OPERATOR & SERVICE MANUAL 071-33370-400 ISSUE 2009/06 Rev.
INTRODUCTION Connections of the DC Power Dist. Chassis are detailed here for clarity. This picture of the DC Distribution Chassis show typical connections and values used in the assembly of the machine. Master Control Relays & Safety Interlocks DC Distribution Chassis Fuses & Master Control Relays 420T V6LT OPERATOR & SERVICE MANUAL 071-33370-400 ISSUE 2009/06 Rev.
INTRODUCTION Master Control Relays: Electric safety interlock switch Inside The Computer Chassis: Please pay regards to the warning that you should NOT remove the Compact Flash without first shutting down the system and turning power off! Inside The DC Distribution Chassis Inside The DC Distribution Chassis: Inside The Computer Chassis 420T V6LT OPERATOR & SERVICE MANUAL 071-33370-400 ISSUE 2009/06 Rev.
INTRODUCTION Transfer Conveyor Sensors These sensors monitor the flow of paper into and out of the transfer conveyor. The Station 1 sensor checks to see that a folded package has arrived telling the system there are no jams inside the folder. The Exit sensor watches to see that a folded package has left the transfer conveyor.
INTRODUCTION A.2f EMERGENCY STOP INTERLOCKS The main E-stop located on the operator panel will interrupt power to the conveyors and folder when pressed down. All motors will halt immediately. This switch must be twisted to bring it back to it’s original upper position. An extra contact is provided on this E-stop switch that is routed to pins 30 and 33 of the Inserter Connector located on the adaptor plate on the end of the cabinet.
INTRODUCTION Folder Interlocks Accumulator Section Under the cover located over the accumulator section On the top cover of the folder. 420T V6LT OPERATOR & SERVICE MANUAL 071-33370-400 ISSUE 2009/06 Rev.
INTRODUCTION Under the cover (removed) of the Transfer Conveyor Lower Cover Under 2 & 4 Buckle Plates On the lower cover under the (#2 & 4) buckle plates On the folder and transfer conveyor meeting point (interrupts power when the transfer conveyor is removed). 420T V6LT OPERATOR & SERVICE MANUAL 071-33370-400 ISSUE 2009/06 Rev.
INTRODUCTION A.3 Machine Specifications Counter Modes: Total count, batch count, resettable count. Listed below are specifications for the 420T: Output Conveyor Options: Throughput Version 1—with shingling output conveyor/stacker Speed: Max. 24,600 documents per hour Version 2—with intelligent transfer conveyor interface to gripper arm of inserter’s insert station.
INTRODUCTION • Test – Press to enter diagnostic screens (for more information, refer to Section G). GBR Line Code • Setup – Press to enter setup screens (for more information, refer to A.7). Bar Code (3 of 9), (2 of 5) (128) • Power On/Off Indicator: Displays status of machine. • Release Brakes – Releases and activates Accumulator and Feed Brakes to allow jam clearing. A.4 RUN SCREEN Information Displayed: • Revision (Software) and Build Date – top line • Packages – Total package counter.
INTRODUCTION A.5 KEYBOARD OPERATION RUN / STOP • Press to start motors and enter ready mode. • Press while in ready mode to shut down the 420T. • (Press E-Stop to shut down the 2 Stage Conveyor) START CYCLE • Press quickly to feed one sheet. • Repeat until EOG on display is showing a “1” then press purge to release the package. PURGE E – STOP the up position.
INTRODUCTION A.6 SETUP SCREENS A.6a System Setup Note: The exact screens and functionality are software version dependent. Specific features may be available or not, or have default settings according to the software version. Press Setup while in the Run screen. This screen provides access to all 420T setup screens. Press Run to return to the “Run” screen. Note: Normal factory settings are in bold font. Package Count “Reset”: • Resets total package count (“Packages”) found in Run screen.
INTRODUCTION stops feeding, purges the accumulator and transfer conveyor to the inserter, then powers down automatically. Sheet Length: • Double Arrow Up” button increments to standard sheet sizes: A6, 8.5”, • 11”, 14”, A4, and A5 “Single Arrow” buttons adjust sheet length in tenths of an inch (range = 63 to 154) • Select job size by entering the number of sheets to run. When selected, the “Batch Off” button changes to “Set Sheets.
INTRODUCTION A.6b Feeder Setup Timed: • (Default) “Timed Off to On” and “Timed On to Off” must be set when using this option. Once the clutch is activated and the document is fed, by default it is turned off when the lead edge of the document is detected by the feed sensor. These timed settings vary how long the clutch stays off and how long it stays on. Read: • Clutch is off at lead edge of page, on after read received. Timed Off to On (Extended Clutch Off Time) • Use when “Timed” is selected.
INTRODUCTION A.6c Accumulator Setup First Page Hold: • Point: Relative number for the position where sheets stop on the • • Accumulator ramps. Starting point for the Vacuum Feeder is “26”, Friction Feeder is “8”. Off: First Page Hold feature is disabled. FPH On: If the Accumulator is equipped with First Page Hold, with “FPH On” selected the first document of a package is held on the Accumulator Ramps while the previous package is released to the Folder.
INTRODUCTION A.6e Xfer Cvyr (Transfer Conveyor) Setup • 3 selects only the final station of the Two Stage Conveyor • 4 Bypass Bridge plus 2-Stage Conveyor • 5 Folder Exit Station and Collector Collect Subsets: • Off (default) or On. Off = no subsets.
INTRODUCTION A.6f Infeed Setup Cutter – 1: • Guillotine type cutter/feeder Printer: • Select when inline with a printer. Settings in bottom section of this screen must also be selected. Cutter-RA: • A guillotine cutter set in right angle configuration feeding onto a right angle or turning device then feeding into the accumulator. Cutter-ST: • A cutter feeding directly into the accumulator.
INTRODUCTION Off Delay – Time: OMR: • This timer value is the period of time after the 420T has been stopped (by pressing the Start/Stop key) that the system waits for the printer to finish sending paper. The feeder has stopped but the 810, IF-42, and creeper keep running and collecting paper. (Upon the 420T stopping, a FULL signal (W-1:18) was sent to the printer). • default, used with GBR Systems F40 Line Code Readers GBR OMR: • Not used on 420T V6 A.
INTRODUCTION • Enables viewing the version of line code reader software. Also verifies A.6i Inserter Setup 0 communication with read board if a version is returned. OMR Sensors • Enables viewing the action of the sensor signals in the monitor window for diagnostic purposes. A.6h Bar Read Setup Inserter Protocol • Select either “Inserter” or “InserterP” The following I/O points have dual usage depending on Protocol selected and interface PCB used (002D-08138 or 002D-07599). Note: Refer to Section A.
INTRODUCTION • This is a representation of the inserter stations and depending on active 1-05 = Separation Sol #1 Inserter P Data Bit #2 1-06 = Separation Sol #8 Inserter P Data Bit #3 1-07 = Shingle Conv Motor Inserter P Kicker selection each will be green “indicating selected on” or red indicating deselected. Degree: • Encoder Updated as Inserter runs.
INTRODUCTION Inserter Control Module. When the pack aligns with an Insert station that it is supposed to get an insert from the ‘<‘ changes to the number of the Inserter Station Select it is aligned with. Xfer at Stations: • Normally set to “Open (Open Feed)” for when the 420T places the folded Example: documents directly on the inserter track.
INTRODUCTION Bad Pack Stop: • This box is defaulted “on” or “checked.” The machine will stop on a bad pack and enable the bad pack indicator light on the inserter. If unchecked or “off”, the machine will not stop on a bad pack. Subset: • Select the “Subset By Count” function in either Barcode or Linecode by entering a subset page count then selecting “Remove” in the Inserter Setup, Subset function.
INTRODUCTION Example of “Inserter Station Swapping” set-up on the GBR • Example: If you want a decode for insert feeder 4 to pull from insert feeder • 1 set 1 = 4 If you want a decode for insert feeder 1 to pull from insert feeder 4 set 4 = 1 Demand Degree: Check to see if the example at the left is needed now that the above screen is present. • This is similar to setting dwell time on an engine.
INTRODUCTION PM Divert – (Postal Meter Divert): A.6k Inserter Setup 2 • (see “Inserter Setup 3” on following page) • This is normally set On At 10, Off At 10, Station 9, Point 9. Insert Station Vacuum: • On is normally enabled at “100.” This is the position of the encoder (in • • degrees) at which vacuum is applied to the insert station. Logical Shift is normally set to “On At: 90.” This is used to carry the data with the physical document. Bad Pack Stop is normally set to “On At: 80.
INTRODUCTION A.6l Inserter Setup 3 • Is normally set to On At 10. This will enable the postal meter at the correct time. This value may need to be adjusted if the postal meter doesn’t place the postage in the correct place. Postal Meter 2 (found in Inserter Setup 3) should then be set to 40 higher than the new Postal Meter 1 value and Postal Meter 3 should be 40 higher than Postal Meter 2. Off At: • Should be set to “10" for all three.
INTRODUCTION Enter the weight of each insert in stations 1-6 and stations 7-12 A.6m Inserter Setup 4 3 (3000 to 3999) On Deg 290 4 (4000 to 4999) On Deg 270 5 (5000 to 5999) On Deg 250 6 (6000 to 6999) On Deg 230 7 (7000 to 7999) On Deg 210 8 (8000 to 8999) On Deg 190 9 (9000 to 9999) On Deg 170 10 (10000+) 150 On Deg In Track Check – Time: 180 • This refers to the InserterStation1/InserterOpenFeed/InserterIntrack • sensor.
INTRODUCTION A.6n Engineering Values (Password Protected) • For settings, refer to Section A.8 for the default Engineering Values List. Reset to Default: • Press this button to reset only the current Engineering Value displayed to its default value. This value is changed on the display only. Pressing the The above screen permits adjustment of the Engineering Values of program control and machine parameters.
INTRODUCTION • Press Ok on the keypad to accept input and move to the next Engineering Value Number. A.6o Exit Comm Setup Type: • • • • • • • • • • • • • • • • • 0 No Comm 1 Spec D1 2 Spec D2 3 Spec P1 4 Spec P2 5 General 6 Tampa 1 (default) 7 Zaandam 1 8 Friedberg 1 9 General 2 10 Zaandam 2 11 Crestwood 1 12 General 3 13 Spec L1 14 Zaandam 3 15 Crestwood 2 16 Zandam 3 Host Simulator Start Button – Xmits test data in type selected. Displays response terminated by a CR, LF. Press again to stop.
INTRODUCTION A.7 GBR LINE CODE READ SYSTEMS OPTION Reader Board Values that can be Adjusted Through The 420T Touchscreen A.7a Introduction Refer to “Line Read Setup 4”. The Line Code Recognition System is capable of decoding line code marks that are on 1/8" or 1/6" spacing. There can be as many as 25 mark locations in a bank with a possibility of two banks per each channel of Line Code marks. A Single Line Code Recognition card supports input information from two probes.
INTRODUCTION A.7b 420T Line Read Setup Screens (GBR & BB+H) Line Read Setup 1 FIRST PAGE – : Used with Page Seq Down EOG on first page of sel. Page Seq Dn to 4, last page and End Of Group generated. LAST ONLY - When this option is selected, the system looks not both and not neither. 1ST ONLY – SetIt enable verify extact data.
INTRODUCTION The purpose of the Group Set mark is to ensure pages from two different packages do not get processed in a single package. Group Set marks must be present when using GROUP SEQUENCING. • First Pg – • Last Pg – • Off – Ink Mark: PAGE SEQUENCE: • PAGE UP - Choose if the page is counted UP (1, 2, 3, 4). • PAGE DOWN - Choose if the page is counted DOWN (4, 3, 2, 1).
INTRODUCTION Line Read Setup 2 GS2 GS4 GS8 PS1 PS2 PS4 PAR NOTE: Presence of a bar is binary 1, and the absence of a bar is binary 0. The GRV mark must be located in the first position. The EOG, PAR, GSn, and PSn marks may be shifted in the bank of marks. The GS grouping and the PS grouping must be located as sets, however. Probes A/B: • Select the reading probe to be used.
INTRODUCTION GS4 GS2 GS8 GS1 PS1 PS4 PS2 PS2 PS4 PS1 PAR PAR This is crucial to proper reading, and the operator should have a master code template that shows the location and value of each line in a code field. If certain fields are omitted, enter an arbitrary number not related to the specific code in that field. Example: Where the code is page field first, and there are three lines for the page field the correct set-up would be Begin: 01 Length: 03 Max value: 7 Line Read Setup 3 Group Seq.
INTRODUCTION Line Read Setup 4 (TJ Read Sys - Obsolete) EOG At Mark: (“Setup” > “Line Read” > “Setup 4”) • Purpose - Controls the size of dynamic packages by indicating the end of a group. • Usage - A solid bar is placed in this location on the page with the largest page ID number. All other pages within a group should have no mark in this area.
INTRODUCTION A.8 LASER BAR CODE READ OPTION A.8a Laser Safety To prevent possible exposure to laser light that may exceed the CDRH’s Accessible Emission Limit for a Class II laser, Your Model 30 has a “Scanning Safeguard” feature, a Laser Shutoff Flip Panel. It shuts off the laser power if the mirror wheel fails to rotate, which ensures that a stationary laser beam cannot exit the scan head. This is a required feature, and it should not be tampered with. Use only in case of an emergency.
INTRODUCTION A.8b Bar Code Basics A bar code is a group of rectangular bars and spaces arranged in a preset pattern. The pattern is organized to represent elements of data referred to as characters. The standard industry codes can represent several alphanumeric characters. There are many different types of bar codes. Each type uses its own symbology, which defines how the bars and spaces represent the letters and numbers. The figure below shows each part of a bar code.
INTRODUCTION A.9 Setting the 420T to Read Laser Bar Code Start: “Setup” > “Bar Read” This will turn the laser on continuously to hand test the lasers positioning. The screen will read BAR READ: and an audible beep will sound when the laser reads the code. The results of the read will be shown on the screen. Reset Job Defaults: Sets the bar job selected to its defaults, erasing any modifications that may have been done in the setups. Press OK to set the job A.
INTRODUCTION Bar Read Setup 1 Read First • The first sheet (Banner Page) of the document is read. The page count information is used to determine how many more sheets to feed and not read. After the last non-read sheet is fed, the next fed sheet will be scanned by the barcode reader to process the next document group. BOG Mark Group Chg CustID Chg Group Seq: Purpose - Identify each page as being a part of an individual package.
INTRODUCTION Purpose - Identify each individual page within a package. The sequential incrementing of the number ensures the documents are assembled in the proper order. Page Up - Min to Max within sets. Usage - This location is used to maintain an even number of solid marks within a code. Note: The fields that are marked Optional can be eliminated by operator configuration of the machine. However, when a data field is eliminated package security and integrity suffers. Page Down - Max to Min within sets.
INTRODUCTION Bar Read Setup 2 • Length_Bit (0 to 30). Number of bits. • IncType Page Seq Code: • • • • Start (0 to 30). Start character. Length (0 to 3). Number of characters. Start_Bit (0 to 30). Starting bit position within character. Length_Bit (0 to 30). Number of bits. Inserts Code: • • • • Start (0 to 30). Start character. Length (0 to 20). Number of characters. Start_Bit (0 to 30). Starting bit position within character. Length_Bit (0 to 30). Number of bits.
INTRODUCTION Bar Read Setup 3 • StartBit Unseal Code: • Start • Length Stitch Code: • StartBit • LengthBit No Stop: • Max. Errors Subset: • By Count Item Verify: Total Page Code: • • • • • Start (0 to 30). Start character. Length (0 to 5). Number of characters. For bit management use the following. Start_Bit (0 to 30). Starting bit position within character. Length_Bit (0 to 30). Number of bits. Sq Stop Code: • • • • • Start (0 to 30). Start character. Length (0 to 20). Number of characters.
INTRODUCTION Bar Read Setup 4 • Off – disables code group matching Customer ID Code: • Start – Customer number, group ID or other number can be found • beginning with this character in the Bar Code. Length – Number of lines after the start, i.e. start=6 length=3 (From the gatemark the start is found at line 6 and the length is line 6, 7 and 8) Code Lengths: -1 disables reading in each category, 0 enables reading with variable length and any number indicates length, e.g.
INTRODUCTION ADDENDUM I • The actual order of the meters after the end of the Inserter should be Hi to Overview • The Postal Meters must be positioned after the last index position of the Lo weight, PM1, PM2, PM3. Inserter and all meters must be stacked as close as possible together. This document outlines the setup of the Postal Meters, Weight Calculation and Operation of Postal Metering on the GBR 420T. Note: The order of postal meters to weight was reversed at 26412.
INTRODUCTION • Enter Meter “OFF AT:’ in degrees, 0 to 350. Before 90 degrees. • Enter Meter Position ‘STA: • 1 to 12 after envelope insert station. • ‘0’ to Disable this meter. • Enter Point Option ‘PT:’ • 9 = Postal Meter Divert - DEFAULT • 10 = Postal Meter Divert - Inverted Signal Inserter Setup 3: Postal Meter 2: • Enter Meter “ON AT:’ in degrees, 0 to 350. After 90 degrees. • Enter Meter “OFF AT:’ in degrees, 0 to 350. Before 90 degrees.
INTRODUCTION Weight Calculation Three Meter Example Postal Meter Selection Calculation. Done when pack is transferred to the Inserter. Package Weight = Envelope Weight + (No. Pages * Page Weight) + (Insert1 * Insert1 Weight) + (Insert2 * Insert2 Weight) + . . . through 8 inserts. Meter 2 to 3 Weight Break Value = 20 Package Weight Meter 1 Meter 2 Meter 3 X If Package Weight is greater than or equal(>=) to Meter 1 to 2 Weight Break Value • Then Meter 1 operates.
INTRODUCTION Inserter Setup 3: • Postal Meter 2 • 240. Meter “ON AT:’ in degrees. • 10. Meter “OFF AT:’ in degrees. • 6. Meter Position ‘STA:’ (6 stations after envelope insert station). • 1. Enter Point Option ‘PT:’ (1 = Select Station 7) • Postal Meter 3 • 280. Meter “ON AT:’ in degrees. • 10. Meter “OFF AT:’ in degrees. • 6. Meter Position ‘STA:’ (6 stations after envelope insert station). • 2. Enter Point Option ‘PT:’ (2 = Select Station 8) • Postal Meter Weights • 30. Meter 1 to 2 Weight Value. • 20.
INTRODUCTION Two Meter Example Meter 1 to 2 Weight Break Value = 99. Must be greater than any pack expected. Meter 2 to 3 Weight Break Value = 20 Package Weight Meter 2 Meter 3 6 X 11 X 19 X 20 X 26 X 31 X • Postal Meter 2 • 200. Meter “ON AT:’ in degrees. • 10. Meter “OFF AT:’ in degrees. • 6. Meter Position ‘STA:’ (6 stations after envelope insert station). • 1. Enter Point Option ‘PT:’ (1 = Select Station 7) • Postal Meter 3 • 240. Meter “ON AT:’ in degrees. • 60.
INTRODUCTION based on the ‘ON AT’ degree for each meter. The first meter in line tested at 200 degrees. The second meter inline required some delay and was tested at 240 degrees. At higher speeds, packs imprinted with the first meter inline were mistakenly being imprinted by the second meter inline unless its ‘ON AT’ degree was slightly delayed. Addendum II NA = Not Available 0) No Comm. Exit Communication is disabled New 438/420T - Exit Interface Serial Communication Specification January 21, 2003— V.
INTRODUCTION • End of Bag. NA. 4 ‘0’ - ‘7’ ASCII numbers 0 to 7, 30 hex to 37 hex. Barcode character 4 6 ‘0’ - ‘9’ ASCII numbers 0 to 9, 30 hex to 39 hex. Barcode character 6 • Bit 0 = Station 10 • Bit 1 = Station 11 • Bit 2 = Station 12 • Future NA.. 7 CR ASCII Carriage Return, OD hex 5 ‘0’ - ‘9’ ASCII numbers 0 to 9, 30 hex to 39 hex.. Barcode character 5 Notes • Characters 1 to 6 are set to ‘9’, 39 hex, if the pack is not valid. • A 5 msec delay between characters is used.
INTRODUCTION • Bit 2 = Pack Valid, Good Pack 7 CR ASCII Carriage Return, OD hex. 3) Pinnacle 1 Protocol: Character 1 Data Description Notes ‘0’ -’7’ ASCII numbers 0 to 7, 30 hex to 37 hex. Characters 1 to 6 are set to ‘9’, 39 hex, if the pack is not valid. • Bit 0 = Station 1 • Bit 1 = Station 2 • Bit 2 = Station 3 2 There is no acknowledge or response from the inserter 4) Pinnacle 2 Protocol: ‘0’ - ‘7’ ASCII numbers 0 to 7, 30 hex to 37 hex.
INTRODUCTION • Bit 0 = 0 • Bit 1 = Sequential Stop Clear Accumulator Pack • Bit 2 = Sequential Stop Stop and Retain Accumulator Pack 6 ‘0’ – ‘7’ ASCII numbers 0 to 7, 30 hex to 37 hex. 4 ‘0’ — ‘9’ ASCII numbers 0 to 9, 30 hex to 39 hex. • Package Page Count - Count 0 to 9 pages.(> 9, 3A hex, 3B hex etc) 5 ‘0’ - ‘7’ ASCII numbers 0 to 7, 30 hex to 37 hex.
INTRODUCTION • Bit 1 = Station 2 • Bit 2 = Station 3 2 1 • Acknowledge from the Inserter that previous transmittal was accepted and ‘0’ —’7’ ASCII numbers 0 to 7, 30 hex to 37 hex next transmittal can be made. Previous package has moved forward an index position. • Bit 0 = Station 4 • Bit 1 = Station 5 • Bit 2 = Station 6 3 ‘0’ ASCII number 0, 30 hex. Notes: • Package Page Count – Count 0 to 9 pages.(>9, 3A hex, 3B hex etc.
INTRODUCTION 6 • Bit 1 = Station 2 • Bit 2 = Station 3 ‘0’ - ‘7’ ASCII numbers 0 to 7, 30 hex to 37 hex. • Bit 0 = Postal Sort Mark, Ink Mark, Kick Mark, Envelope Mark • Bit 1 = Divert by Read Mark, Divert by Read Errors • Bit 2 = Pack Valid, Good Pack 7 CR 7 ‘0’ - ‘7’ ASCII numbers 0 to 7, 30 hex to 37 hex.. • Bit 0 = Station 4 • Bit 1 = Station 5 • Bit 2 = Station 6 ASCII Carriage Return, OD hex. 8 ‘0’ – ‘7’ ASCII numbers 0 to 7, 30 hex to 37 hex.
INTRODUCTION 3 ‘0’ - ‘7’ ASCII numbers 0 to 7, 30 hex to 37 hex. There is no acknowledge or response from the inserter • Bit 0 = Station 7 • Bit 1 = Station 8 • Bit 2 = Station 9 General Notes • There is no acknowledge or response from the Inserter except for 6) 4 ‘0’ - ‘9’ ASCII numbers 0 to 9, 30 hex to 39 hex, • • Package Page Count - 10’s digit • 5 ‘0’ - ‘9’ ASCII numbers 0 to 9, 30 hex to 39 hex.
INTRODUCTION • • • • • • • Station 3 = 1 Station 4 = 0 Station 5 = 1 Station 6 = 0 Station 7 = 1 Station 8 = 0 Station 9 = 1 The selected protocol formats the test data and sends the message. 420T V6LT OPERATOR & SERVICE MANUAL 071-33370-400 ISSUE 2009/06 Rev.
PREVENTATIVE MAINTENANCE B.2a2 Cleaning the Fold Rollers SECTION B PREVENTATIVE MAINTENANCE B.1 Test equipment and tools • • • • DO NOT USE ANY LIQUID ON THE FOLD ROLLERS! The fold plates must be removed in order to clean all fold rollers. For more information on cleaning the fold rollers, refer to your 420T Operator Manual. ·Portable Scope Meter ·Standard & Metric Hex Wrenches ·Small Blade Flat Screwdriver ·Philips Head Screwdriver B.
PROBLEM ANALYSIS C.1 “TEST” SCREEN OPERATION The speeds indicated are approximate (inches per second). Diagnosis of the system begins with these tests. If it is found that the displayed information indicates a problem, refer to the schematics in section D or section F. NOTE: The FEED and READ speeds must be within 5% of each other to ensure normal operational condition. C.2 IO/144 BOARD (INPUTS AND OUTPUTS) C.
PROBLEM ANALYSIS C.2b I/O Reference Tables 420T V6LT I/O Table 0 To help understand the "Input/Output (I/O) Test" screen it needs a little introduction. We will concentrate on only the block of numbers on the left side of the screen. At the top there are two rows of numbers. The numbers in the top row are assigned interrupts for the Input & Output system hardware addresses in the second row.
PROBLEM ANALYSIS C.2c I/O Reference Tables 420 V6LT I/O Table 1 Rack Opto Type Description C.
PROBLEM ANALYSIS C.3 GENERAL SOLUTIONS TO ERRORS Many error codes are the result of jammed paper (physical errors), or paper expected at specific time and location (read errors: sequence, blank page, misprinted code, etc.). The sensors index the number of sheets as they pass, incrementing a count on the CPU-186. If a corresponding decrement of count does not occur from the next sensor, a read error is generated. If error persists, consider failure of sensor or communication problem (poor connection, etc.).
PROBLEM ANALYSIS C.3b ERROR CODES Each error is displayed using a combination of numbers that are coded to give the operator/maintenance personnel an idea of where to begin to look for the problem when an error occurs. The error codes (five digits) are designed to be unique. The first three digits specify a machine area or module. The last two digits define the specific error relating to an event in some location which occurred during operation.
PROBLEM ANALYSIS Feeder Module: 120nn/8nn 12001 "Feeder; No Feed Error” 12020 “DOUBLE PAGE FED” 13030 “Max Track Pages Exceeded - Remove Pack” Folder Module: 140nn/8nn 12021 "Below Minimum Speed" 12022 “LONG PAGE FED” 12023 “EXTRA PAGE WAS FED ” 12025 “FEED TO ACCUMULATOR JAM (TIME)” 12026 “SPEED LOW” 12027 (Deleted!) 12028 (Not Used!) 12029 (Not Used!) 14001 “Jam In Folder - Pack Not Seen At Folder Exit” 14002 “Jam At Folder Exit” 14020 “SPEED LOW” 14021 "Folder Exit Sensor Ja
PROBLEM ANALYSIS 15026 "Unkown Pack Sta 1 - Set Pack Bad" 15052 "No Data From Sta 2 - Set Sta 3 Pack Bad" 15027 "Unknown Pack Sta 2 - Set Pack Bad" 15053 "Data Overwrite Sta 3 - Set Sta 3 Pack Bad" 15028 "Unknown Pace Sta 3 - Set Pack Bad" 15054 "No Data From Sta 3 - Set Sta 4 Pack Bad" 15029 "Unknown Packs - Remove Packs" 15055 "Data Overwrite Sta 4 - Set Sta 4 Pack Bad" 15030 "Jam Out Of Folder, Into Collector Ramps" 15056 "No Dat From Sta 1 - Set Sta 4 Pack Bad" 15031 "Jam On Collec
PROBLEM ANALYSIS 21005 “IF-42 Conveyor Output Paper Jam - Clear Jam” 21006 “810 Right Angle Not Ready - Check Power” 21007 “IF-42 Conveyor In/Out Paper Jam - Clear Jam” 21008 “Printer Response Timeout - Nothing Received” 21015 “Cutter Output Feed Timeout” 21016 “Cutter Interface Output Sense Timeout” 21017 “Cutter Interface Count Exceeded” 21019 “Cutter Interface Input Sense Jam” 21020 “Cutter Interface Output Sense Jam” 21021 “Cutter Output Feed Timeout” 21022 “Cutter Interface Input
PROBLEM ANALYSIS EVENT CHECK: Exit Demand and Exit Sense, Inserter Station 1 Sense C.3c (11xxx) System Error Description CHECK VALUE: — 11020 “Exit Demand Timeout” ADJUST VALUE: — When a package in the accumulator does not leave the accumulator within a given time this error will be displayed. EVENT: Accum. Package Ready to Exit Demand ANALYSIS: Inserter Station 1 Sense covered for 6 demands. Sensor blocked 11025 "NOT READY" EVENT CHECK: ExitDemandTimer CHECK VALUE: 60 sec.
PROBLEM ANALYSIS 12020 “DOUBLE PAGE FED” Did the motor start? WHAT HAPPENED No? The Double Page sensor sensed more than one page as it was fed throught the sensor. Check the motor, motor controller, and the connections and wiring to these. For an optical sensor: The sensing light beam goes through one page but not two or more pages. Yes. For an ultrasonic sensor: The ultrasonic beam senses an air gap between two or more pages. ACTION TO TAKE Adjust the Feed singulator properly.
PROBLEM ANALYSIS 12023 “EXTRA PAGE WAS FED” Check Feeder Setup, Pulse Feed is set to Read. This cycles the Feeder clutch and brake on every page fed. WHAT HAPPENED The Feeder was not processing a page feed, did not expect a page fed and sensed a page fed at the Feeder Sensor. Increase the Feed To Accum. Time, Engin. Value 24, to allow more time. 250 to 300 is normal.
PROBLEM ANALYSIS C.3e (13xxx) Accumulator Error 13003 “Max Accu. Pages Exceeded - Remove Pack” Description WHAT HAPPENED 13000 “Stack Error” WHAT HAPPENED A sheet entering the Accumulator, has not entered the accumulator ramp sensor/accumulator stack sensor and left within 500 msec. ACTION TO TAKE Check for any obstruction along the paper path at the entrance to the accumulator. Check setup and adjustment of the accumulator ramp sensor sensor. ANY ADJUSTMENTS - None.
PROBLEM ANALYSIS 13021 “Un-Expected Pack Present - Remove Pack” The pack must be inspected or removed from the accumulator. WHAT HAPPENED ANY ADJUSTMENTS The machine was powered up with a pack in the accumulator being sensed by the accumulator sensor/accumulator presence sensor. Adjust the Accumulator Setup FPH Point down to stop the page faster. ACTION TO TAKE Check operation of the accumulator FPH clutch and brake in the Test IO144 screen.
PROBLEM ANALYSIS sensor plus the current number of pages collected in the inserter track section would exceed the maximum number of pages that can be collected in the inserter track. WHAT HAPPENED Cycling, a count of packs entering the folder minus the number exitng exceeding 2 packs. ACTION TO TAKE ACTION TO TAKE The pack must be removed from the accumulator, from under the accumulator sensor to proceed with operation. Check for a jam in the Folder. ANY ADJUSTMENTS Test the Folder Exit Sensor.
PROBLEM ANALYSIS 14021 "Folder Exit Sensor Jam" HARDWARE: Accum Type=Flats, System Exit Device=Conveyor, System Exit Device=Xfer,Xfer XcvyN=ON. Check the motor controller setups. WHAT HAPPENED C.3g (15xxx) Xfer Conveyor (Xfer Cvyr, Xcvy) Cycling, a pack is sensed at the Folder Exit Sensor for too long a time(240msec). Error ACTION TO TAKE 15001 “Jam Error” Check for a jam at the Folder.Exit Sensor Description EVENT: Pack at Xcvy Sta. 1/In Sensor, increment. Pack at Xcvy Out Sensor, decrement.
PROBLEM ANALYSIS 15003 “Jam At Out Sensor Error” Cycling, a pack was sensed at the xfer conveyor exit with no data associated with it HARDWARE: Original Xfer Conveyor ACTION TO TAKE WHAT HAPPENED Cycling, a pack did not leave the Xfer Conveyor Out Sensor within a time. For Inserter Open Feed - Check the Inserter Station 1/In Track Sensor. For Inserter Gripper - Check the Xfer Conveyor Out Sensor. ACTION TO TAKE Check Xfer Conveyor and Inserter setups. Check for a jam at the Xfer Conveyor Exit.
PROBLEM ANALYSIS Adjust Engin Value#7 Xcvy Clutch On Time to place 3 packs evenly in the Original Xfer Conveyor. 15021 “Jam Out Of Xfer Cnvy Station 1" —The last pack should be about 1 inch from the exit rollers. 15021 “Jam Out Of Xfer Station 1" If packs are pulled from the Original Xfer Conveyor data remains because there are no sensors at Stations 2 and 3.
PROBLEM ANALYSIS 15022 “Jam into Xfer Station 2” Test the sensor at Station 2. HARDWARE: New Xfer Conveyor, Bridge and Two Stage Test the clutch and brake at the Station 2. 15022 “Jam Into Xfer Station 2" ANY OTHER ADJUSTMENTS WHAT HAPPENED Adjust Engin Value#9 XcvyN OutOf Sta time. Cycling, a pack did not reach Xfer Station 2 within a time. This pack was marked bad. ACTION TO TAKE Was there an Xfer Conveyor error in the previous cycle? Check for a jam in the Xfer Station 1 or 2.
PROBLEM ANALYSIS Set Engin. Value#55 to 1 to set all packs in the Xfer Conveyor bad. The following device, maybe an Inserter, may have provision to divert bad packs for inspection. 15025 "Jam out of Xfer Station 3” ACTION TO TAKE Test the sensor at Station 1. Test the clutch and brake at Station 1. ANY OTHER ADJUSTMENTS HARDWARE: New Xfer Conveyor, Bridge and Two Stage This pack was marked bad.
PROBLEM ANALYSIS The following device, maybe an Inserter, may have provision to divert bad packs for inspection. 15030 “Jam Out of Folder, Into Collector Ramps” HARDWARE: Collector 15028 “Unknown Pack Sta 3 – Set Pack Bad” WHAT HAPPENED HARDWARE: New Xfer Conveyor, Bridge and Two Stage Cycling, a pack did not leave the Folder and reach the Collector within a time. WHAT HAPPENED At Power On, Motors On, an unexpected pack was sensed in Xfer Station 3. ACTION TO TAKE Check for a jam in the Folder.
PROBLEM ANALYSIS 15032 “Jam Out Of Collector” Set Engin. Value#55 to 1 to set all packs in the Xfer Conveyor bad. HARDWARE: Collector WHAT HAPPENED The following device, maybe an Inserter, may have provision to divert bad packs for inspection. Cycling, a pack did not leave the Collector within a time. 15037 “Missing Pack Sta 2 – Set Sta Empty” ACTION TO TAKE HARDWARE: New Xfer Conveyor, Bridge and Two Stage Check for a jam at the Collector.
PROBLEM ANALYSIS 15038 “Missing Pack Sta 3 – Set Sta Empty” HARDWARE: New Xfer Conveyor, Bridge and Two Stage 15040 “False Feed Into Xfer Station 1” WHAT HAPPENED At Power On, Motors On, a pack was not sensed as expected at Xfer Station 3. HARDWARE: New Xfer Conveyor, Bridge and Two Stage WHAT HAPPENED ACTION TO TAKE Cycling, an unexpected pack was sensed at Xfer Station 1. Test the sensor at Station 3. ACTION TO TAKE Test the clutch and brake at Station 3.
PROBLEM ANALYSIS Test the clutch and brake at Station 1. Set Engin. Value#55 to 1 to set all packs in the Xfer Conveyor bad. ANY OTHER ADJUSTMENTS The following device, maybe an Inserter, may have provision to divert bad packs for inspection. Did this pack stop under the Station Sensor? Adjust sensor, turn Xfer Conveyor speed down, check Xfer Conveyor brakes. 15042 “False Feed Into Xfer Station 2" This pack was marked bad.
PROBLEM ANALYSIS ACTION TO TAKE Remove and inspect this pack and other suspect packs or allow the pack to be diverted for inspection downstream. Test the sensor at Station 2. Set Engin. Value#55 to 1 to set all packs in the Xfer Conveyor bad. Test the clutch and brake at Station 2. The following device, maybe an Inserter, may have provision to divert bad packs for inspection.
PROBLEM ANALYSIS Xfer Station 4 is a data holding location for data passed to an exit device such as an Inserter Was there an Xfer Conveyor error in the previous cycle? Remove and inspect this pack and other suspect packs or allow the pack to be diverted for inspection downstream.
PROBLEM ANALYSIS WHAT HAPPENED This pack was marked bad. Cycling, a pack reached Xfer Station 3, but the pack from Xfer Station 2 has no data. Was there an Xfer Conveyor error in the previous cycle? Remove and inspect this pack and other suspect packs or allow the pack to be diverted for inspection downstream.
PROBLEM ANALYSIS 15055 " Data Overwrite Sta 4 - Set Sta 4 Pack Bad” ACTION TO TAKE HARDWARE: New Xfer Conveyor, Bridge and Two Stage Had the Xfer Station 1 pack previously entered Xfer Station 1 normally, no error? WHAT HAPPENED Cycling, the pack data reached Xfer Station 4, but the data from the previous pack associated with Xfer Station 4 is still present.
PROBLEM ANALYSIS 15059 “Data Overwrite Sta 1 - Set Sta 1 Pack Bad” ANY OTHER ADJUSTMENTS This pack was marked bad. HARDWARE: New Xfer Conveyor, Bridge and Two Stage Was there an Xfer Conveyor error in the previous cycle? WHAT HAPPENED Remove and inspect this pack and other suspect packs or allow the pack to be diverted for inspection downstream. Cycling, a pack reached Xfer Station 1, but the data from the previous pack associated with Xfer Station 1 is still present. Set Engin.
PROBLEM ANALYSIS Bad UARTs (Universal Asynchronous Receiver Transmitter) Serial chip C.3g (16xxx or 18xxx) Reader 16052 “READLESS READ ERROR ” Bad software. (NN=16 BAR READ MESSAGES OR NN=18 LINE READ MESSAGES) Bar Code Reading Errors Error Description nnn04 “SHORT GROUP” Check the page to determine if error is valid Cause/Remedy Check read setup again. nnn01 “GROUP NUMBER OUT OF SEQUENCE” Check for correct feed speed.
PROBLEM ANALYSIS nnn07 “INVALID GROUP” nnn12 “NOT ENOUGH NV-RAM” Group is not part of set. The program has run out of non-volatile ram. Check to see that the proper barcode is printed on the page and that the barcode matches the specifications. You should never get this error. If you do get this error, either the software is bad or the CPU board is bad. nnn13 “PRESETS CORRUPT” Check to see that the proper barcode job is selected.
PROBLEM ANALYSIS nnn17 “INVALID PIC INT” (Invalid "Programmable Interrupt Controller" interrupt) nnn24 “NO BANK 2 GATE MARK” Reader was expecting two sets of read code, one was missing Hardware failure on reader board Reader set up improperly Battery failed or battery jumper missing Code is physically missing Bad CPU-586 board Check to see that the proper barcode job is selected nnn18 “INVALID SETUP DATA” nnn25 “CALIBRATION OUT OF RANGE” Reader board memory corrupted Calibration failed Restart machine C
PROBLEM ANALYSIS nnn29 “EXPECTED READING” nnn36 “GROUP NUMBER CHANGED IN SET” Blank page Every page within a set is supposed to have the same group number and the page that was just fed did not. Read encoder failed If the group did not change within the set, check to see that the proper barcode is printed on the page and that the barcode matches the specifications. Paper jam Feed sensor out of adjustment Check to see that the proper barcode job is selected.
PROBLEM ANALYSIS Make sure that the barcode print on the paper is good quality. nnn42 “MAX PAGE NOT = NO. PAGES” (Bar Reading) Incorrect page count in accumulator Page count setting incorrect EOG mark not seen Read error nnn47 "PAGES GREATER THAN ACCUMULATOR MAX" More pages were fed than was set in the "Accumualtor Max. Sheets" section of the "Accumulator Setup" screen. Check the tension between the Retard Roller and the Feed Belt to prevent to ensure extra sheets are not slipping out.
PROBLEM ANALYSIS nnn56 "SETUP TIMEOUT ERROR" ADJUST VALUE: Engin. Value 17 nnn57 "NO READ DATA" ANALYSIS: Time exceeded, A demand for paper was sent to infeed device (i.e., feeder), but paper was not detected by the feed sensor within the time frame set in engineering values. nnn99 "UNDEFINED ERROR" C.4 E-STOP PROBLEMS AND ANALYSIS C.4a Troubleshooting the E-stop / Interlock System C.
PROBLEM ANALYSIS The following pictures are intended to be helpful in the procedure for correcting a malfunction of the E-Stop System. 1. Check the 24VDC at F1A, page 25, Figure 4, if no value check DC power supply. 2. Check for blown fuse (F2A, 100ma SB, loop string) if blown, check for a shorted interlock which may be grounded. (wire touching a ground point) 3.
PROBLEM ANALYSIS 4. If all check ok, could be a bad guard module, contactor for switch AC and DC could have a bad contact on aux contactor module located on top of the two contactors opposite E-Stop/Gate Panel. The assembly shown on this page is located in the top portion of the main control cabinet. One side contains the main relays, K1 and K2, as well as the main contactor fuse panel. These fuses are for the fan, the computer power supply, and the DC power supply.
PROBLEM ANALYSIS GBR 420 Inserter Screen List Diagnostic Description Overview: 4 Station Screen Readout The GBR 420 Inserter Interface passes a pack to the inserter track at an open station or a gripper arm. Once the pack is sensed “In Track”, the pack is tracked through the inserter stations by indexing the data one station at a time when a Demand Feed Signal is received from the inserter at each cycle. The Inserter Interface performs an inserter action based on the pack data at a particular station.
PROBLEM ANALYSIS Position: ‘c’ is Envelope, Inkmark(Kick, Postal Sort), Divert weighted as 1, 2, 4 and added. 0 to 7. 6331 5411 4501 3000 2000 1000 0000 0000 6411 5501 4000 3000 2000 1000 0000 0000 Div. Ink. Env. 'c' 0 0 0 0 0 0 1 1 0 1 0 2 0 1 1 3 1 0 0 4 1 0 1 5 1 1 0 6 1 1 1 7 6501 5000 4000 3000 2000 1000 0000 0000 6000 5000 4000 3000 2000 1000 0000 0000 Inserter SetUp list Example: 6000 5000 4000 3000 2000 1000 0331 0331 • Pack in Open Feed; No.3; Sta.
PROBLEM ANALYSIS 420T/438 - Barcode Data Specification 3 - 2D - Rev.3 A total of 22 characters are used. Overview This document outlines a simple specification using a standard 2D Data Matrix Barcode. This simple specification provides basic security for feeding grouped documents with a 420T/438. Group and page sequencing assure that an accumulated group is complete, no extra pages, no missing pages and no missing groups.
PROBLEM ANALYSIS 0 = disable; 1 = enable BARREAD SETUP1 Bit 3 – inserter station 3 select 0 to 1 0 = disable; 1 = enable Bit 4 – inserter station 4 select 0 to 1 0 = disable; 1 = enable Bit 5 – inserter station 5 select 0 to 1 0 = disable; 1 = enable 1 Normal Group Seq Up Group Seq Min=1 Max=99 Page Seq Page Up Page Seq Min=1 Max=9 Count Skip=1 Ink Mark Off B2 – Second set of Bit Fields 0 to 31 Meter Divert Off Bit 1 – inserter station 6 select 0 to 1 Subset Mark Off UnSeal Mark
PROBLEM ANALYSIS PmDivert Code Start=0 Length=0 Start_Bit=0 BARREAD SETUP3 Total Page Code Length_Bit=0 Start=0 Length=0 Seq. Stop Code Start=0 Start_Bit=0 Subset Code Start=0 Start_Bit=0 UnSeal Code Start=0 Start_Bit=0 Staple Code Start=0 Start_Bit=0 No Stop Max. Errors=0 Subset By Count=0 Item Verify Off Item Verify Min.=0 Check Digit None Start_Bit=0 Max.=0 BARREAD SETUP4 ReadFeed Type Feed&Read Read&Feed Start Delay Reader Chn One Customer ID Seq.
Tables Example1: Page Group Seq. Page Seq.
Tables BarCode Character to Value to 5-Bit Value: Value Bar Code Hex Bi ts Binary 8 Decimal ASCII 7 6 5 4 3 2 1 Character 0 0 00 0 0 0 0 0 1 1 01 0 0 0 0 1 2 2 02 0 0 0 1 0 3 3 03 0 0 0 1 1 4 4 04 0 0 1 0 0 5 5 05 0 0 1 0 1 6 6 06 0 0 1 1 0 7 7 07 0 0 1 1 1 8 8 08 0 1 0 0 0 9 9 09 0 1 0 0 1 A 10 0A 0 1 0 1 0 B 11 0B 0 1 0 1 1 C 12 0C 0 1 1 0 0 D 13 0D 0 1 1 0 1 E 14 0E 0 1 1 1
Tables M 22 16 1 0 1 1 0 N 23 17 1 0 1 1 1 O 24 18 1 1 0 0 0 P 25 19 1 1 0 0 1 Q 26 1A 1 1 0 1 0 R 27 1B 1 1 0 1 1 S 28 1C 1 1 1 0 0 T 29 1D 1 1 1 0 1 U 30 1E 1 1 1 1 0 V 31 1F 1 1 1 1 1 420T V6LT OPERATOR & SERVICE MANUAL 071-33370-400 ISSUE 2009/06 Rev.
PROBLEM ANALYSIS To define the Extraction of Demand Feed: Char. Position 1 2 3 4 5 always start at 1 and count up from left to right. 1 8 9 0 9 Define Demand Feed Start = 1 Define Demand Feed Length = 5 Demand Feed Data Extracted = “18909” number for the math. for this example. Must use the entire number. “18909” is converted to a Define Demand Feed Start = 1 Define Demand Feed Length = Must use the entire number. 5 Demand Feed Data Extracted = to a number for the math.
PROBLEM ANALYSIS 1 8 9 0 9 8(NT) Barcode Setups for this example. Define Insert Start = No decoding. 8-Bit values. Bit Positions 8-6-5-4-3-2-1. A listing of Barcode extraction setup sections. 1 Define Insert Length = number. 5 Demand Feed Data Extracted = number for the math. Must use the entire Group Seq Code Start (0 to 30). Start character. Length (0 to 5). Number of characters. “18909” “18909” is converted to a Define Insert Bit Start = 10 Start_Bit (0 to 30).
PROBLEM ANALYSIS Length (0 to 20). Number of characters. Used with Normal-A or Reverse-A, multiple character numeric values, 8 8 8 001000 9 9 9 001001 A 10 A 001010 B 11 B 001011 Start_Bit (0 to 20). (1 to 30)Starting bit position within character. Ink Mark Code Start (0 to 30). Start character. C 12 C 001100 Length (0 to 20). Number of characters. Used with Normal-A or Reverse-A, multiple character numeric values, D 13 D 001101 Start_Bit (0 to 20).
PROBLEM ANALYSIS S 28 1C 011100 T 29 1D 011101 U 30 1E 011110 V 31 1F 011111 W 32 20 110000 X 33 21 110001 Y 34 22 110010 Z 35 23 110011 - 36 24 110100 . 37 25 110101 Space 38 26 110110 $ 39 27 110111 / 40 28 111000 + 41 29 111001 % 42 2A 111010 This is called End Of Set, End Of Group(EOG), End Of Collation(EOC) or Demand Feed(DF). Common Demand Feed: Normal • A Bit or Mark only set on the last page fed.
PROBLEM ANALYSIS • Demand Feed First Page does not expect a Demand Feed Mark on pages other than the FIRST page fed.(“UNEXPECTED EOG”). • EOG Mark At defines where the Demand Feed mark is. BOG Mark • BOG is Beginning Of Group. • This is a mark only on the first page fed. All other pages no mark. Last Only EOG Mark At defines where the BOG mark is. • A Gate and/or Demand Feed Mark only set on the last page fed. • All other pages blank. Ignores blank pages.
PROBLEM ANALYSIS • This is a mark only on the first page fed. All other pages no mark. • Demand Feed Code defines where the BOG bit is. Group Change • This recognizes a change of Group Sequence (numeric) on the first page fed. • Group Sequence Code defines where the Group Sequence data is. Customer ID • This recognizes a change of Customer ID (alphanumeric) on the first • page fed. Customer ID Code defines where the Customer ID data is.
PRINTED WIRING BOARD INFORMATION D.1 CPU PC104 (SAT520) CARD 2. BCR Com Ports 3. Not Used 4. Floppy Disk Port 5. Printer Port 6. COM 2 Serial Port 7. Touch Screen Port 8. SVGA Port D.1b General Description CPU SAT 520 Card GBR Part Number: 042-31117-500 D.1a Features Video, I/O, up to 4 Serial Interface (RS232 Ports), two floppy drive interface, Internet and LPT1 Port. The SAT-520Plus is a highly integrated PC/104 and PC/104Plus expandable module with x86 compatibility and standard PC-AT architecture.
PRINTED WIRING BOARD INFORMATION D.2 I/O 96 Daughter CARD GBR Part Number: 042-31578-500 Configuration • Jumpers as shown in diagram • J1 to touch screen • J1 to RS232 connector on cabinet bulkhead J16 to floppy drive D.3 Single Channel Read Card GBR Part Number (software will be different depending on whether the board is used for GBR Line Read Code or BB+H type Line Read Code): 042-26908-500 I-O Daughter Card D.3a Function: D.
PRINTED WIRING BOARD INFORMATION D.3b LED Indications: The following LED indications apply only when using BB+H line code. • LED 1 ON/OFF every second indicating operation (except when LED 2 is • • • lit) LED 2 ON indicates busy: line code read taking place, calibration read taking place, or machine speed sample being done. LED 3 ON indicates line codes will be read using calibration data that has been stored. OFF indicates line codes will be read without using calibration data that has been stored.
PRINTED WIRING BOARD INFORMATION D.6 Line Code Read Card GBR Part Number: 042-26908-500 Two Channel Switching Card Line Code Read Card This card is mounted separate from the rest of the computer but is connected with cables. The read card is used for both GBR Line Code and Bowe Bell & Howell Line Code. The difference is the software to perform the read criteria. 420T V6LT OPERATOR & SERVICE MANUAL 071-33370-400 D.
INTERFACE TO INSERTING EQUIPMENT SECTION E. INTERFACE TO INSERTING EQUIPMENT The 420T is designed to be run on-line with the inserter. It can be docked to any of the insert stations, however, station #1 is preferable. Before the 420T may be mated up to the Inserter there are a few pieces on the Inserter which need to be removed or repositioned. The parts to be removed are the hopper side and rear plates, T-plate, and insert cushion cup. The singulator finger and cushion cup mount must be repositioned.
INTERFACE TO INSERTING EQUIPMENT This is the zero, ‘0’, degree position, the Inserter Home position. • Note the Degree Display is 0 when the gripper arm is fully into the pocket IF NOT REPEAT THE PROCESS E.2 Removal of insterter's Hopper Side Plates NOTE: View of Inserter Hopper is from rear of inserter. • • • • 1. Remove four screws holding side plate adjustment shaft blocks. 2. Remove shaft E-clips. 3. Unlock right side plate and slide off end of shaft. 4.
INTERFACE TO INSERTING EQUIPMENT • 4. Jog the inserter slowly through one cycle, observing mount closely. You will notice that as the mount swings downward it will bottom against the shaft behind it. If it does not, swing mount further down and cycle the inserter again. E.2c 420T INTERFACE COUPLING Gripper Arms Orientation to 420T Singulator Finger The machine is designed to permit the operator to connect the 420T directly to the inserting device.
INTERFACE TO INSERTING EQUIPMENT • 3. Install switch block on small shaft, with the switch to the top, rear. Looking end on, block should have 5 degree tilt towards other shaft. If shaft is not long enough use universal bracket, on outer frame cover, or deck. Magnetic Block Switch Block and Bracket • 6. You are now in the input test section. Connect demand switch to the • 4. Install double magnet block on large shaft. NOTE: Do not tighten yet: • snug one screw. 5.
INTERFACE TO INSERTING EQUIPMENT E.3 Transfer Conveyor Adjustments E.3a Package overhang at last station When a package is being presented to the gripper arm (last station of the Transfer conveyor) the package should have only the Trailing edge of the folded document held by the flat green belts. Positioning the trailing edge of the document even with the center line of the lower-most forward shaft accomplishes the desired document position.
INTERFACE TO INSERTING EQUIPMENT • 4. The Transfer conveyor will index in response to the Dump command. If E.4 Setup of Demand switch the package that was placed just before the exit sensor stops at the Demand Switch Adjustment and Setup discharge end of the Transfer conveyor the interrupt is being seen by the control card. However if the document is throughout the end of the Transfer conveyor then the interrupt is not being seen by the control card.
MISCELLANEOUS F.1 Software Rev Update using E-Mail a:\diskmon.bin [Boot Monitor] The disk for the New438/420T is specifically bootable on the New438/420T. This boot software is not normally visible and cannot be copied from one disk to another. The entire disk must be ‘disk copied’ or ‘copy disked’. F.2 GBR OMR Reader Set-up Reader Pre-Amp: The application software (‘GBR420.exe’) is visible and can be copied to and from an e-mail, another disk or from the hard disk of a computer.
MISCELLANEOUS F.3 Read Zone Diagrams: Line Code Placement 420T V6LT OPERATOR & SERVICE MANUAL 071-33370-400 Bar & 2D Code Placement ISSUE 2009/06 Rev.
MISCELLANEOUS F.4 Engineering Values These values are to be used as a starting point. These values may vary, depending on type and weight of paper being processed, environmental conditions, and system tolerances, in order to obtain optimal performance.
MISCELLANEOUS 19 20 21 0 “Test ExitComm Test List Switch” (Range: 0 > 255, Inc: 1) 0 = No extra ExitComm (Comm3) list messages. 1 = Extra ExitComm list messages, times in msec, Demand time, receive character (for Sure-Feed). Bit level assignment: (D7 D6 D5 D4 D3 D2 D1 D0. D7 > D1 = unassigned D0 = ExitComm messages 0 “Exit Demand Switch” (Range: 0 > 1, Inc: 1) Applies to Hopper Fill and Conveyor. 0 = No Exit Demand required. 1 = Exit Demand required (for Conveyor for Sure-Feed).
MISCELLANEOUS 37 38 39 40 41 42 0 2 0 1 0 70 “Exit comm. Xmit Retries” (Range: 0 > 2, Inc: 1) 1 + Default. In Tampa 1 only, if no Ack Response is received defined in EV#36, a retry is initiated and sends a duplicate serial string. A range of 0->2 retries can be indicated before the machine stops and displays the error: “Exit Comm: No Message Response (E20801)”. (See EV#36 for time setting).
MISCELLANEOUS 0 “ReadLess Read Mode” (Range: 0 > 1, Inc: 1, Default = 0) 0 = Default. Normal operation. 1 = Special error recovery routine when using Demand Feed type “Read first” in barcode for FPF-35. 1 “First pack Dumped Error Enable” (Range: 0 > 1, Inc: 1, Default = 1) 1 = Default. Normal operation. 0 = Disables setting bad pack on first pack processed after startup or purge. 1 “Feed & Accum pack Error Enable” (Range: 0 > 1, Inc:1,Default = 1) 1 = Default. Normal operation.
MISCELLANEOUS Insert Sta.:00: F.5 Typical Postal Metering Setup Presets Postal Meter Divert: The following are ‘Typical Presets’ for the 438 configured for 6-Station AC/DC Open Feed Inserter Control with two postal meters, Meter 2 and Meter 3, Meter 1 and Meter 2. This may vary from your actual application.
