FPi-4030 Service Manual (Rev.1.2)

FPi 4030 Inserting System

Service Manual

Illustrated Parts List

Operator Manual

Release: 07/2006 Revision: 0

Item number: 51.0067.1001.00

SERVICE MANUAL FPi 4030 INSERTING SYSTEM

Page i–2

NoteIf you as a user of these documents should detect any difference to actual practical operation, or simple printing errors, please assist us in publishing error-free documents for the future by forwarding these errors with a copy of the faulty page to the address listed below. Any information and data contained in these documents will thus always be up to date. Thank you.

Your technical trainers

These service instructions contain copyright information. No part of these instructions may be copied or otherwise reproduced without prior written consent by Francotyp-Postalia.© 2006 Francotyp-Postalia

Francotyp-Postalia GmbH

Triftweg 21-26

16547 Birkenwerder, Germany

FP release 07/2006: Ingenieurbüro Dr. Helbig, Berlin


Overview of the Service Documentation

1 THIS MANUAL

2 HEALTH, SAFETY AND ENVIRONMENT

3 GENERAL DESCRIPTION

4 USER INTERFACE

5 THE FPI 4030 INSERTING SYSTEM

6 FAULT FINDING

7 UPGRADING AND INSTALLING ACCESSORIES

8 TECHNICAL SPECIFICATIONS

9 ILLUSTRATED PARTS LIST

10 APPENDIX

11 FPI 4030 OPERATOR MANUAL

Please Note: Current versions of the illustrated spare parts list,recommended spare parts stock, wear parts and error messages can be looked up online in the Service Knowledge Database (SKD).


Item number: 51.0067.1001.00 Page i–3


Page i–4


Contents

Contents

1 This Manual.................................................................................................... 1-1

1.1 Abbreviations ..................................................................................................... 1-1

1.2 Terminology ....................................................................................................... 1-1

1.3 Release note...................................................................................................... 1-1

2 Health, Safety and Environment .................................................................. 2-1

2.1 Safety instructions.............................................................................................. 2-12.1.1 General ................................................................................................ 2-12.1.2 Electrical safety .................................................................................... 2-1

2.2 Symbols on the machine and in the manual ...................................................... 2-1

2.3 End of life ........................................................................................................... 2-2

3 General description....................................................................................... 3-1

3.1 The system......................................................................................................... 3-1

3.2 Denominations ................................................................................................... 3-1

3.3 Paper flow .......................................................................................................... 3-2

3.4 Process Description ........................................................................................... 3-23.4.1 Document feeders................................................................................ 3-53.4.2 Document transport.............................................................................. 3-53.4.3 Collator................................................................................................. 3-63.4.4 Document folder................................................................................... 3-73.4.5 Envelope feeder ................................................................................... 3-93.4.6 Insert and exit track.............................................................................. 3-9

3.5 Electronics........................................................................................................ 3-113.5.1 PCB functions .................................................................................... 3-113.5.2 Schematic overview ........................................................................... 3-123.5.3 Connection with PC (Concorde application) ...................................... 3-133.5.4 The ID-tag (99.45.04)......................................................................... 3-143.5.5 Software package compatibility check ............................................... 3-16

3.6 Optional features.............................................................................................. 3-173.6.1 Optical Mark Recognition (OMR) ....................................................... 3-173.6.2 Flex Optical Mark Recognition (Flex OMR)........................................ 3-173.6.3 High capacity BRE MaxiFeederTM .................................................... 3-173.6.4 Insert‘n FrankTM (not available yet)................................................... 3-173.6.5 Online services................................................................................... 3-183.6.6 Intermediate transport ........................................................................ 3-18

4 User interface................................................................................................. 4-1

4.1 Operator menus ................................................................................................. 4-1




Contents

4.2 Job and Supervisor menus................................................................................ 4-1

4.3 Service menu .................................................................................................... 4-14.3.1 System settings ................................................................................... 4-2

4.3.1.1 Configuration ...................................................................... 4-24.3.1.2 Localisation......................................................................... 4-24.3.1.3 Software versions ............................................................... 4-34.3.1.4 Reset data .......................................................................... 4-34.3.1.5 Power up............................................................................. 4-34.3.1.6 Folder offset........................................................................ 4-34.3.1.7 Flap closer offset ................................................................ 4-3

4.3.2 Job settings ......................................................................................... 4-44.3.2.1 System output (FPi 4030 only) ........................................... 4-44.3.2.2 Document offset.................................................................. 4-54.3.2.3 BRE offset........................................................................... 4-54.3.2.4 Secure jobs......................................................................... 4-64.3.2.5 Flap closer .......................................................................... 4-6

4.3.3 Service Tests....................................................................................... 4-64.3.3.1 Photocells ........................................................................... 4-64.3.3.2 Digital inputs ....................................................................... 4-74.3.3.3 Actuators tests .................................................................... 4-84.3.3.4 Run in ................................................................................. 4-84.3.3.5 DFC test.............................................................................. 4-9

4.3.4 Service counters................................................................................ 4-104.3.5 OMR .................................................................................................. 4-10

4.3.5.1 OMR code definition ......................................................... 4-104.3.5.2 Read-code test ................................................................. 4-11

4.3.6 Diagnostics........................................................................................ 4-134.3.6.1 Start test ........................................................................... 4-134.3.6.2 Error counters ................................................................... 4-134.3.6.3 Last error list ..................................................................... 4-13

4.3.7 Online service.................................................................................... 4-144.3.7.1 Server port ........................................................................ 4-144.3.7.2 Reset CB data .................................................................. 4-144.3.7.3 Test CB............................................................................. 4-14

4.3.8 Remove blockage.............................................................................. 4-154.3.9 Sealing on franking machine (not yet available)................................ 4-15

5 The FPi 4030 inserting system .................................................................... 5-1

5.1 Transport, storage and installation .................................................................... 5-15.1.1 Transport ............................................................................................. 5-15.1.2 Unpacking and storage ....................................................................... 5-15.1.3 Installation ........................................................................................... 5-3

5.2 Mechanical description...................................................................................... 5-55.2.1 (Dis)assembly - Covers and plates ..................................................... 5-55.2.2 (Dis)assembly - Electrical components ............................................. 5-105.2.3 (Dis)assembly - Feeder modules and vertical transport right-hand... 5-15

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Contents

5.2.4 (Dis)assembly - Feeders .................................................................... 5-195.2.5 (Dis)assembly - Vertical transport ...................................................... 5-315.2.6 (Dis)assembly - Collating area ........................................................... 5-325.2.7 (Dis)assembly - Folder ....................................................................... 5-365.2.8 (Dis)assembly - Main drive mechanism inserter ................................ 5-505.2.9 (Dis)assembly - Envelope feed .......................................................... 5-595.2.10 (Dis)assembly - Upper unit................................................................. 5-655.2.11 (Dis)assembly - Envelope transport ................................................... 5-735.2.12 (Dis)assembly - Envelope sealing and ejection ................................. 5-755.2.13 (Dis)assembly - Sensors .................................................................... 5-765.2.14 Adjustment ......................................................................................... 5-91

5.3 Electrical description ...................................................................................... 5-1025.3.1 Display board (FPi 4030 only).......................................................... 5-1035.3.2 Keyboard.......................................................................................... 5-1045.3.3 Motor relay board ............................................................................. 5-1055.3.4 Connection board............................................................................. 5-1065.3.5 Communication board (optional) ...................................................... 5-1085.3.6 Main board ....................................................................................... 5-1125.3.7 ID-tag (99.45.04) .............................................................................. 5-118

5.4 Maintenance................................................................................................... 5-119

6 Fault finding................................................................................................... 6-1

6.1 Remotely resolving problems............................................................................. 6-1

6.2 Error handling..................................................................................................... 6-2

6.3 Error Codes........................................................................................................ 6-3

7 Upgrading and installing accessories......................................................... 7-1

7.1 Conveyer stacker (FPi 4030 only)...................................................................... 7-1

7.2 OMR................................................................................................................... 7-1

7.3 MaxiFeederTM (FPi 4030 only).......................................................................... 7-1

7.4 Online services................................................................................................... 7-1

7.5 Insert‘n FrankTM (not yet available)................................................................... 7-1

7.6 Intermediate transport ........................................................................................ 7-1

8 Technical Specifications............................................................................... 8-1

8.1 Technical specifications ..................................................................................... 8-18.1.1 Machine specifications ......................................................................... 8-18.1.2 Documents ........................................................................................... 8-38.1.3 Envelopes ............................................................................................ 8-5

8.1.3.1 Insert specifications............................................................. 8-68.1.4 Capacity feeders and exit options ........................................................ 8-78.1.5 Fold types............................................................................................. 8-7




Contents

8.1.6 Processing speed................................................................................ 8-88.1.7 Configuration dimensions.................................................................... 8-98.1.8 System operation control .................................................................. 8-108.1.9 Other general specifications.............................................................. 8-108.1.10 Quality ............................................................................................... 8-108.1.11 Operating modes .............................................................................. 8-108.1.12 Optical Mark Recognition .................................................................. 8-11

8.1.12.1 Concept ........................................................................... 8-118.1.12.2 Reading marks and their meaning by level....................... 8-118.1.12.3 Format of the Marks.......................................................... 8-128.1.12.4 Reading Head Location .................................................... 8-128.1.12.5 Options ............................................................................. 8-12

8.1.13 Product customisation per country / organisation ............................. 8-12

9 Illustrated parts list....................................................................................... 9-1

10 Appendix...................................................................................................... 10-1

10.1 Process (paper flow) parts .............................................................................. 10-1

10.2 Recommended spare parts ............................................................................. 10-8

10.3 Wear parts....................................................................................................... 10-9

10.4 Electrical diagrams ........................................................................................ 10-10

11 FPi 4030 Operator Manual.......................................................................... 11-1

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This Manual

1 This Manual

Release: 07/2006

1.1 Abbreviations

1.2 Terminology

BRE Business Reply EnvelopeCCW Counter clockwiseCW ClockwiseDFC Double Feed ControlLH Left-handOMR Optical Mark RecognitionRH Right-handGUI Graphical User InterfaceHMI Human Machine Interface

Term Description

Double Feed Control (DFC)

Double Feed Control is the sensor that measures the thickness of a sheet to check if the inserting system does not accidentally take more sheets than intended. DFC sensors exist on Feeders (double sheet detection). Currently DFC's on Francotyp-Postalia inserting systems perform relative measurements, which means that they need a cycle to 'learn' the thickness of a sheet.Also the length of the document is measured so partly overlapping sheets will be detected.

Leading Situation in which the top of the sheet is closest to the separation unit in a document feeder.

Pane Cycle The various documents of a set are fed from the feeders in such a way that these documents are partly overlapping each other. This pane-like overlapping ensures a higher throughput.

Sequential Cycle Documents are transported along the vertical track without touching each other. Only after joining the set in the making they do touch each other.

Shunting The partially completed set in the collator is moved from the collator area in the direction of the fold unit (short shunt) or into the fold unit (long shunt).

Trailing Situation in which the bottom of the sheet is closest to the separation unit in a document feeder.

1.3 Release note

This manual is based on service documentation for 70.1 and 62.2 machines, rev. 01.0 - 03/2006, provided by Neopost.

Revision: 0

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This Manual

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Health, Safety and Environment

2 Health, Safety and Environment

Release: 07/2006

2.1 Safety instructions

2.1.1 General

• This machine must be operated by competent personnel. The manufacturer accepts no responsibility for accidents or inju-ries caused by operation by incompetent personnel.

• Covers may only be opened by skilled persons, who know the risks involved.For safety reasons, the machine will not function with opened covers.

• Keep away long hair, fingers, jewellery, etc. from rotating and moving objects of the system.

• Switch off the system at the end of the day.

2.1.2 Electrical safety

• The power connection must be easily accessible, preferably close to the machine.

• For safety reasons it is essential that the machine is connected to a socket outlet with protective earth connection.

• The machine is provided with an over-current protection (20 A). It is assumed, however, that the main power supply is provided with a circuit protection as well.

• Disconnect the machine from the power supply when it is not in use for a longer time.

• Potential hazard may exist to electronic hardware in conditions with static electricity. It is advised that, when handling electronic parts, an earth connected wrist band is used in order to be per-manently discharged from static electricity.

2.2 Symbols on the machine and in the manual

WarningThis symbol identifies situations where improper use of the machine can result in personal injury or permanent/catastrophic damage to the machine.This symbol also indicates to consult the operator manual in relation to this action.

WarningThis symbol indicates a danger caused by high voltage.

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Health, Safety and Environment

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2.3 End of life

The objectives of the European Community's environment policy are, in particular, to preserve, protect and improve the quality of the envi-ronment, protect human health and utilise natural resources prudent-ly and rationally. That policy is based on the precautionary principle and principles that preventive action should be taken, that environ-mental damage should as a priority be rectified at source.

Separate collection of waste is the precondition to ensure reuse and recycling of waste that is generated at the disposal of electrical or electronic equipment and is necessary to achieve the chosen level of protection of human health and the environment in the European Community. More particularly, certain materials and components of waste electri-cal and electronic equipment needs selective treatment as their inju-dicious handling or disposing of on or into land, water or air would represent a major threat to the environment and human health.

In order to facilitate collection and treatment separated from normal domestic waste, electrical and electronic equipment is marked with the following logo:

Do not mix with normal domestic waste.Please use the subjoined return or

collection system dedicated to electricaland electronic waste.

Equipment produced afterAugust 13, 2005

Not only are you by law not allowed to dispose of the waste equip-ment via other waste-streams. The manufacturer encourages you to actively contribute to the success of such collection and to the com-mon good and better quality of life of present and future generations.

For more information on the correct disposal of this product please contact your local Francotyp-Postalia dealer.


General description

3 General description

Release: 07/2006

3.1 The system

The system feeds, folds and inserts documents into envelopes and then seals and stacks the envelopes. The system is equipped with a variety of special features as programmable jobs, Fill & Start, Flex-Feed™, double feed control, hopper swap, multifeed, daily mail, Power-Fold™, and automatic collator stop positions.

3.2 Denominations

Q OPRST JKL

N

JM

A B C

F

G

H

I

D

E

A Envelope catch tray K SensorsB Envelope slide L BellowsC Display with operating buttons M Handle for clearing stoppagesD Upper unit N Water reservoirE Locking hand grip upper unit O Side cover (opened)F Document feeders P RulerG Collator arm Q Thumb wheel for side guide adjustmentH Collator area R Side guides envelope hopperI Power inlet, power switch S Knob for separation adjustmentJ Knobs for clearing stoppages T Envelope support bracket

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General description

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3.3 Paper flow

1

2

3

4

5

For denomination of all parts, see Section 10.1 “Process (paper flow) parts”.

The documents are vertically transported from the document feed-er(s) (1) to the collator (2). When the required documents are collect-ed, the document pile is transported horizontally to the document folder (3). After folding, the documents are inserted into an envelope by the inserter (5). Finally, the envelope is sealed and transported to the envelope receiving tray.

3.4 Process Description

The processing of documents by the system can be divided into a number of distinct sequential partial processes. These processes will be discussed in some more detail:• Document feeders• Document transport• Collator• Document folder• Envelope feeder• Insert and exit track


General description

Release: 07/2006

The figure on the next page shows a schematic overview of the proc-ess. All mechanical items that are strictly necessary to explain the process are projected on the left-hand side of the machine. This im-plies that not all auxiliary mechanical items (such as gears and belts) are shown.

See Section 5.2 “Mechanical description” and Section 9 “Illustrated parts list” for more details on the mechanics.

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General description

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1

2

34

56

7

8

9

10

9a

11

12

13

14

15

16

1718

19

2021

22

23

24

25

26

27

28

2930

31

32 33

34

35

36

3738

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

5556

57

58

59

60

61

62

63

64

65

66

67

68

69

70

71

72

73

74

75

76

77

78

79

80

81

M2

M1

MS3

MS2

MS1

PH10

PH7

PH8

PH11

PH9

PH6

PH5

PH4

PH1

PH2

PH3

TX

TX

RX

RX

RX

TX

TX

RX

TX

RX

TX

RX

TX

TX

RX

TX

RX

RX

TX

RX TXDFC3

DFC2

DFC1

CL8

CL6/7

CL5

CL1

CL2

CL3

So3

So2

So1

PD1

PD4

PD3

PD2

CL4

FE3

FE2

FE1

For denominations of all parts, see Section 3.3 “Paper flow”.


General description

Release: 07/2006

3.4.1 Document feeders

The system has three types of feeders. Feeders with:• manual separation• automatic separation• a choice between automatic separation and no separation at all

(i.e. daily mail)

For the documents to be fed the following rules apply:• Documents with the fold types single fold, letter fold, and double

parallel fold must be fed with the orientation face up and leading. The address carrying document is to be fed by the highest active feeder.

• Documents with the fold type zigzag fold must be fed with the ori-entation face down and trailing. The address-carrying document is to be fed by the lowest active feeder.

The feeding process• A document is separated by 79 - 81 (feeder 3), 72 - 74 (feeder 2)

or 65 - 67 (feeder 1).• The document is exited to the vertical track by 77 and 78 (feeder

3), 70 and 71 (feeder 2) or 63 and 64 (feeder 1).• The paper transport is monitored by the feeder photocell PH3

(feeder 3), PH2 (feeder 2) or PH1 (feeder 1).• The thickness is measured by the thickness measuring unit (DFC

unit) DFC3 (feeder 3), DFC2 (feeder 2) or DFC1 (feeder 1). • The feeders are mechanically driven from the main motor M2 by

a clutch (feeder clutches CL1 - CL3).

3.4.2 Document transport

Depending on the number of documents to be delivered by each feeder there are two ways in which documents can be transported along the vertical track: pane cycle and sequential cycle.

• Pane Cycle: The various documents of a set are fed from the feeders in such a way that these documents are partly overlapping each other. This pane-like overlapping ensures a higher throughput.

• Sequential Cycle: Documents are transported along the vertical track without touching each other. Only after joining the set in the making they do touch each other.

The transporting area• The vertical track consists of one driven axle per feeder (75, 68,

61), plus one driven axle in the lower vertical track (45). • All these axles carry two rollers, except for 75 (at the top feeder),

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General description

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which carries four rollers. This is necessary for straightening the paper prior to passing the optional reading head.

• The driven rollers have their counterparts in rollers 76, 69, 62 and 44.

• If the OMR option is installed, the paper transport prior to enter-ing the reading head (located directly below PH4) is monitored by the reading head photocell (PH4). This monitoring is necessary for establishing the reading window.

3.4.3 Collator

The following rules apply to the way in which a set is collated (i.e. composed):• The highest active feeder is processed first, the lowest active

feeder last. This is independent of the fold type.• If a feeder adds two or more documents to a set (multi-feeding),

these documents are first of all processed in the order in which they are separated from the feeder hopper.

Based on the actual number of documents from each cycle, the sys-tem composes a set based on the minimum amount of cycles and, if possible, a pane cycle in stead of a sequential cycle (see Section 3.4.2 “Document transport”). In the case of multi-feeding of ’n’ documents from the same feeder there are always at least ’n-1 sequential cycles involved. In the case of OMR processing the document(s) from feeder 3 is/are always processed via sequential cycles.

Shunting

Note The short shunt is only used for the FPi 2000-2.

Shunting is necessary between two successive cycles of the collat-ing process, before a new document joins a partially completed set. During shunting, the partially completed set in the collator is moved from the collator area in the direction of the fold unit (short shunt) or into the fold unit (long shunt). This is necessary to prevent the paper entering from the vertical track from interfering with the partially com-pleted set. The choice between long shunt and short shunt is made in the serv-ice menu through the system output selection. In Mode 1 the long shunt is used, in Mode 2 the short shunt is used.

The collating area• The collating area consists of a set of rollers (46, 50, 53, 56 and


General description

Release: 07/2006

60) that can be driven in both directions by the collator motor (M1), and a set of counter rollers (47, 48, 49, 52, 54, 55 and 58).

• In the reverse direction of the collator motor (M1), documents are fed into the collator area. In the forward direction they are moved out.

• The entry of the paper into the collator area (not the leaving of paper!) is monitored by the collating area photocell (PH5).

The collating process• Documents are fed into the collator area from the vertical track,

or back into the collator area in the second stage of the shunt process.

• The documents are aligned against the relevant automatic docu-ment stoppers (51, 57 or 59).

• During shunting, the collator motor (M1) first turns in the forward direction, then in the reverse direction.

• In case of a long shunt the folding forward clutch (CL4) is acti-vated in the first shunt stage and the folding reverse clutch (CL5) is activated in the second shunt stage (FPi 4030 only).

• Documents are exited from the collator to the fold unit if a set is complete. In that case both the collator motor M1 (forward direc-tion) and the folding forward clutch (CL4) are activated.

3.4.4 Document folder

The folding process is based on the timed "karate" action of a fold plate (one per fold table).• The paper enters a fold table.• The flap is turned upwards.• The fold plate is turned backwards (from its rest position).• The paper is directed into an upward, more or less vertical direc-

tion.• The fold plate moves forward at the right time and pushes the

paper between the pair of upper and lower fold rollers. The fold is located at the place where the paper touches the tangent between the upper and lower fold roller. The timing of the fold plate movement is based on the detection of the paper by the folder input photocell PH6, on machine parameters and on operational fold pa-rameters.

The folding process• The paper of a completed set leaves the collator area. This is

detected by the folder input photocell (PH6). • The paper is transported to the first fold table by the fold input

rollers (42 and 43). The flap (41) moves up, so paper entering the first fold table will be directed in upward direction.

• At the appropriate time, the flap (41) moves back and the fold

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General description

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plate (40), which hinges around an axle (39), moves forward. The first fold will be made.

• Directly after the fold has been made, the fold plate (40) returns to its rest position. This process is controlled by the first fold table clutch (CL6), which drives the curve gear (37), which controls the movement of the fold plate (40) and the flap (41).

• The axle for the curve gear also carries the brake disc (38), the status of which is monitored by a slotted photocell (SPH3).

• The 360 degrees fold cycle of the brake disk consists of a 120 degrees part (flap upwards) and a 240 degrees path (flap down-wards plus "karate" action of 40).

• The brake disc is mechanically loaded by a positioning lever and a torsion spring.

• The hinge axle (39) also carries the lever for the actuator of flap 41. In this way all movements related to the first fold table are synchronized.

• After leaving the fold rollers (35 and 36), the paper enters the second fold table.

• The flap (34) moves up, so paper entering the second fold table will be directed in upward direction.

• The paper guide (33) also moves up. This guide is necessary in the second fold table to retain the fold that has been made in the first fold table.

• The paper is limited to a small area between the paper guide (33) and a fixed vertical guide plate (not shown in the figure, but to the left of 33).

• At the appropriate time the flap (34) moves back and both the fold plate (32) and the guide plate (33), which both hinge around axle 31, move forward. The second fold will be made.

• Directly after the fold has been made, the fold plate (32) returns to its rest position. This process is controlled by the second fold table clutch (CL7), which drives the curve gear (29), which con-trols the movement of the fold plate (32), the paper guide (33) and the flap (34).

• The axle for the curve gear also carries the brake disc (30), the status of which is monitored by a slotted photocell (SPH4).

• The 360 degrees fold cycle of the brake disk consists of a 120 degrees part (flap and paper guide upwards) and a 240 degrees path (flap and paper guide downwards plus "karate" action of 32).

• The brake disc is mechanically loaded by a positioning lever and a torsion spring.

• The hinge axle (31) also carries the lever for the actuator of flap 34. In this way all movements related to the second fold table are synchronized.

• Finally the paper leaves the fold unit on its way (transported by 27 plus 28 and 13 plus 14) to the insert table.


General description

Release: 07/2006

3.4.5 Envelope feeder

• All the rollers for this process stage (1, 4, 6, 8, 10 and 11) are engaged to the main drive by the envelope track clutch (CL8). During the document and insert stage these rollers are disen-gaged.

• The envelope transport subsystem can be manually moved by the right-hand knob, at the left-hand side of the machine.

• The counter rollers (3, 5, 7, 9 and 12) can be de-coupled from there driven counterparts by a counterclockwise movement of the release handle at the left-hand side of the machine.

The envelope feeding process• First of all by the action of the feed and separation rollers (1 and

2) an envelope is separated from the stack in the hopper and transported via three pairs of transport rollers (3 - 8). The enve-lope track photocell (PH7) detects the leading and trailing edge of the envelope.

• The envelope then passes the flap rollers (9 and 10). • The combined action of the flap scraper and the lower linear

speed of the flap rollers (9 to 12) compared with the speed of roll-ers 3 to 8, results in some buckling and the opening of the enve-lope.

• The flap is the trailing part of the envelope passing the flap rollers and the envelope flap track photocell (PH8).

• Pulse measurements (measured via slotted photocell SPH1) dur-ing the presence of the envelope under the photocells (PH7 and PH8) provide information on the length of the not yet opened envelope, the opened envelope and the time at which the enve-lope transport is suddenly stopped with the envelope on the insert table.

• The sudden stop is the result of disengaging by the envelope track clutch (CL8) and the friction brake (9a). The envelope flap now is fixed between two rollers (11 and 12).

• In the final ejecting, sealing and exiting stage the driven rollers are engaged once again to release the envelope (held between 11 and 12) and to feed a new envelope to the insert table.

3.4.6 Insert and exit track

Inserting process• Once the envelope is on the insert table, the fingers solenoid

(So1) is activated. The fingers are moved forward into the enve-lope. The envelope stays in place, for it is fixed between the two rollers (11 and 12). This is a preparation for inserting the docu-ment set into the envelope.

• Now the document set can be inserted. This set leaves the fold

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General description

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unit (transported by rollers 27 plus 28 and by 13 plus 14), is detected by the insert table photocell (PH9) and passes under the fingers before entering the envelope.

• The insert of the set is considered finished if and when the insert table photocell (PH9) detects the trailing edge of the set.

Exiting process• Then a number of actions take place: (a) The clutch (CL8) is acti-

vated to release the flap and to feed a new envelope to the insert table. (b) The insert table solenoid (So2) is shortly activated, resulting in the ejection roller (16) moving down. (By spring action, after switching So2 off, these driven rollers are pulled high again.) Now the envelope is rejected from the insert table. So2 is deactivated after the complete passage of the filled envelope.

• The filled envelope passes rollers 17 and 18, the moistening brushes, the sealing track rollers (19 and 20) and the lower seal-ing roller (22) plus its counter roller (21).

• Now the photocell (PH11) is triggered.• The upper reverse roller (25) is held high (i.e. this roller doesn't

contact the lower reverse roller 24) by a spring. • A certain time after triggering the PH11 the sealing solenoid

(So3) is activated. The envelope is between the upper and lower reverse rollers.

• By the So3 action the upper reverse roller now is temporarily low-ered.

• Given the turning direction of the lower reverse roller, the trans-port direction of the envelope is abruptly changed from an "upstream" to a "downstream" direction. Assuming that the trail-ing envelope edge has passed 21 and 22, this is now the leading edge of the envelope being transported through the sealing roll-ers 22 and 23.

• After passing the sealing rollers the envelope is exited to the exit. • The photocell (PH11) is restored to its rest position. • The exit photocell (PH10) monitors the passing envelope.


General description

Release: 07/2006

3.5 Electronics

3.5.1 PCB functions

The functions of the PCBs from the schematic overviews can be de-scribed as follows:

Board name Function

1 Display board Converts received data into understandable data for the dis-play

2 Key board Contains the start, stop and clear buttons

3 Motor relay board Turns the motor on and off

4a Connection board Provides connection to USB, RS232 and the phone line (see note)

4b Modem board(optional)

Converts digital data (from the processor) into analogue data (for external communication) and the other way around

5 Communication board(optional)

Controls the franking interface and external communication

6 Main PCB Operates the device and controls the user interface

7 ID-tag (99.45.04) Contains information (serial number, encrypted machine op-tions, encrypted total counter)

NoteThe regular connection board only provides connection to USB. The expanded connection board also provides connection to RS232 and the phone-line.

See Section 5.3 “Electrical description” for the location of the PCBs in the system.

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3.5.2 Schematic overview

The electronics and the wiring between the boards in the FPi 4030 can be summarized in a schematic overview.

munication board.
For a device without com
For a device with communication board:

Display board

070.1/062.2

Motor relay

board

100/115,230V ac

24Vdc

Switch mode

Power supply

ID Tag

Connection board

regular

Host

Main PCB

Keyboard

USB device

USB cable

FPi 4030 / FPi 2000-2

Display board

Connection board

Expanded

Communication

board

USB

cable

serial

RS232

(INF)

Phone

Modem

board

Host

Host

Main PCB

Keyboard

ID Tag

USB

device

Motor relay

board

Switch mode

Power supply

070.1/062.2

100/115,230V ac

24Vdc

FPi 4030 / FPi 2000-2


General description

Release: 07/2006

3.5.3 Connection with PC (Concorde application)

Software upgrade andbackup

If you want to upgrade the inserter software or backup information from the inserter, the inserter can be connected to a PC. Special soft-ware has to be installed on the PC to enable communication between the USB port of the PC and the machine. This application is called Concorde.

In Addition to FlashOEM
Concorde is a new application in addition to the FlashOEM applica-tion that is used for the RS232 communication. Both applications can run on the same PC.
The primary functions of Concorde are:• To flash software packages in a complete system (with multiple

boards)• To flash new software directly on a board (factory flash)• To backup inserter information and export it to XML format• To restore information into the inserter from a previous backup

The Concorde application has been developed in such a way so that it requires minimal upgrades in the future. For more information, please see the online help contained in the Concorde application.

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3.5.4 The ID-tag (99.45.04)

Each time the FPi 4030 is started, the presence of the ID-tag (99.45.04) is checked. • If the ID-tag (99.45.04) is not present, all software controlled

options are switched off.• If the ID-tag (99.45.04) is present, its serial number is compared

to the serial number in the FRAM (refer to the following schedule) and the options are read out.

System de-blockage in

service menu

Set Counter manually

(TAG and FRAM)

TAG update flag = ok. END

System blockage error

Call Service

Copy

FRAM Counter to

TAG

Start up: Read Tag and Fram

OK

OK

No3

No2

Yes

Yes1

Yes

FRAM

correct

TAG

correct

No4

No

Yes5

No

Has the ID

tag been

replaced?

Copy

Serial number

Tag to FRAM

Copy

Serial number

Tag to FRAM

Synchtonize

TAG

Counter to FRAM

Copy

Tag Counter to

FRAM

Serial

number Tag=

Serial number

FRAM

Define

latest

counter

TAG

count=FRAM

count


General description

Release: 07/2006

In this schedule, number 1 to 5 can be described by:

1 Normal situation

2 If either FRAM or TAG has been disconnected, the latest counter can be used.

3 PCB or Tag replacement

4 PCB replacement (Tag OK).

5 Tag replacement (new Tag)Note: if incorrect Tag is installed, software controlled options and connectivity will not function correctly.

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The following information is stored on the ID-tag (99.45.04):• Serial number of the machine.• Encrypted machine options.• Total insert counter (kept up to date when the FPi 4030 is run-

ning).

3.5.5 Software package compatibility check

For all systems with (optionally) multiple boards and software ver-sions, Francotyp-Postalia will release packages that contain the sup-ported software versions of each board. The following matrix may be applicable:

Examples Main PCB Communication board

Package 1 version A version A

Package 2 version A version B

Package 3 version B version B

Each software file contains all compatible software versions of the "partner" boards. The system will compare all available software files to know what the highest supported software package is. It is then decided whether the selected software versions are a valid combina-tion or not.


General description

Release: 07/2006

3.6 Optional features

3.6.1 Optical Mark Recognition (OMR)

With this option, computer printed documents can be handled fully automatically.• A code is printed on each document, that contains information

about the processing of the sheets.• The code on the last sheet of the set always contains the insert

instructions.• The other sheets carry the accumulate instruction. • If a parity check is used, this is checked on each sheet. • If the set contains only one sheet, it is the “last” sheet. • The code must appear in the same location on every page

regardless of the actual code length.

OMR can be activated by a system specific license code.

3.6.2 Flex Optical Mark Recognition (Flex OMR)

With this option, also non-Francotyp-Postalia OMR codes and alter-native document handling algorithms can be recognised in the opti-cal mark recognition process. Flex OMR can be activated by a system specific license code and by a customer-specific setting that is saved in a physical dongle.

3.6.3 High capacity BRE MaxiFeederTM

The MaxiFeederTM is a feeder that can be loaded with a high number of documents. This feeder is intended to be used for Business Reply Envelopes (BRE), but also "standard" documents up to 156 mm length can be processed with it. The MaxiFeederTM is auto-detected by the system when it is switched ON. This makes it easy to switch over from the standard document hopper to the MaxiFeederTM and vice versa. To make use of a MaxiFeederTM it is not necessary to (re-)program the jobs.

3.6.4 Insert‘n FrankTM (not available yet)

With this option, inline franking by a connected franking machine can be realised. When a functioning communication line with the franking machine is present, it is also possible to set the franking machine and to select a franking job.Insert’n Frank can be activated by a system specific license code. In order to do this, the communication board and the modem board need to be installed.

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3.6.5 Online services

Online services enable the Sales Organisation to remotely manage and maintain a system that is installed at the customer. This option needs to be activated per system by the sales organisa-tion. In order to do this, the communication board and the modem board need to be installed.

3.6.6 Intermediate transport

An intermediate transport kit (not in combination with OMR) for processing 90-115 mm documents from the top feeder can also be ordered.


User interface

4 User interface

Release: 07/2006

4.1 Operator menus

For an explanation of the Operator menus, see the appropriate Op-erator Manual.

4.2 Job and Supervisor menus

For an explanation of the Job menu and Supervisor menu, see the appropriate Operator Manual.

4.3 Service menu

See the following flowchart for an overview of the various menus:

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4.3.1 System settings

4.3.1.1 Configuration

Use this menu to view and change the following options:• Intermediate transport• Gap separation on feeder 1• OMR reading head installed• FLEX OMR dongle installed (FPi 4030 only)• Online/INF hardware installed• Online services enabled• FM connected• Modem connected

If the configuration, stored in the machine, is updated, the new con-figuration will be stored after: • saving the configuration.• switching the machine off and then on.

4.3.1.2 Localisation

Use this menu to set:• the language of the operational user interface• the service telephone number• the document standard size• machine type• date format

LanguagesEnglish USA, English UK, Dutch, French, German, Spanish, Italian, Katakana, Swedish, Norwegian, Danish, Portuguese, Russian, Hun-garian, Czech

Document standard sizeISO (i.e. metric), Inches, None

ISO sizesA4 (297 mm), A5 (148 mm) and A6 (105 mm) for documents; C5 (162 mm) and C6/5 (114 mm) for envelopes

Inches3.5" (90 mm), #9 (99 mm), 4" (102 mm), 6" (152 mm), 7" (178 mm), 8" (203 mm), 8.5" (216 mm), 11" (279 mm), 12" (305 mm) and 14" (356 mm) for documents; #9 (99 mm), #10 (105 mm) and 6x9 (153 mm) for envelopes


User interface

Release: 07/2006

4.3.1.3 Software versions

This screen gives release information on: the machine software (pro-grammed in the flash memory) for the inserter part, and the optional communications board.

Usually both machine software items should be updated simultane-ously, using external flash software.

4.3.1.4 Reset data

Use this menu to initialize the system with the default values. In ad-dition all photocells will be readjusted (Therefore, make sure all pa-per has first been removed from the machine). The stored counter values are not affected.

4.3.1.5 Power up

In this menu you can select (Yes or No) to display the language menu after machine power up.

4.3.1.6 Folder offset

Two timed cams discs are used for the folding process. There is one cam disc for each folding pocket. The timing is determined by the length of the sheets to be folded.

Given tolerances in the activation times of the clutches involved, this menu provides for an equivalent shift in the folding positions, thus compensating a clutch activation time that deviates from the average value.

In the folder offset menu: 1 Select the folder. 2 Set the equivalent shift in the folding position between -20 mm

and +20 mm. 3 Process test material to see if corrections in these settings are

required.

4.3.1.7 Flap closer offset

Use this menu to adjust the timing of the activation of the sealing so-lenoid (So3). This function can be used to improve the sealing proc-ess. The timing has influence on the position of the filled envelope (with its flap fixed between two rollers) prior to being transported be-tween the sealing rollers. This position can be adjusted between -10 and + 10 mm (with respect to the default envelope position).

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4.3.2 Job settings

4.3.2.1 System output (FPi 4030 only)

Use this menu to select operating mode Mode 1 or operating mode Mode 2, for each of the jobs.

Mode 2 is the default setting.• Mode 1 focuses on the versatility of paper parameters (paper

thickness; document length), i.e.: ensures for correct operation even under the most extreme paper conditions.

• Mode 2 focuses on high speed.

The differences between the two modes are related to the way the documents of a set are collated.

Mode 1 should be used for:• a paper thickness of 65 g/m² or less• a document length of 12 inch or higher

Mode 1 should also be used for some unusual customer-specific ap-plications; Mode 2 should be used for all other jobs.

Background information:If Mode 2 is being used, the paper transport stops as soon as the document that is to be added to the set has entered the collating ar-ea. This is detected by the collator entry photocell. The partially com-pleted set is moved over a short distance to the fold table. This distance is sufficient to prevent the leading edge of the next docu-ment being entered from touching the front of the partially completed set.

The complete set is aligned against the paper stop, once the last document of the set has entered the collating area. It is then trans-ported to the folding area for further processing. Mode 2 focuses on minimal necessary paper displacement. This implies a higher processing speed, but with the potential risk of longer paper contact between the new entering document and the partially completed set.

However, this is not a problem for the usual normal range of paper weights. If Mode 1 is being used, the partially completed set is trans-ported further into the fold table. After each new document that joins the partially completed set this set is aligned against the paper stop. This takes more time, but the paper-to-paper contact occurs over shorter distances. Mode 1 focuses on problem free operation with a wide range of paper types, at some expense of the process speed.


User interface

Release: 07/2006

4.3.2.2 Document offset

The vertical transport of documents fed by the various feeders is ar-ranged in such a way that thedocuments are partially overlapping each other. This overlapping scheme ensures that the documents are properly aligned in the col-lator area.

The extent to which the documents do not overlap each other (i.e. the document offset value) can set for each job in the document offset menu. The default value is 50 mm. The document offset can be var-ied between 20 mm and 75 mm in 1 mm steps.

4.3.2.3 BRE offset

If a document is longer than the set address fold but shorter than the envelope height, this document sometimes will be unnecessarily folded. Under certain conditions, this document can be prevented from being folded. This can be set in the BRE (Business Reply En-velope) offset menu.

An offset can be switched on or off for all jobs; from 1 to Lng (Fill & Start). In the case of offset on the last document that had been added to the set prior to further processing will be shifted from the rest of the set (offsetting), i.e. this document will be held back during a certain dis-tance. This means that the trailing edge of this upper document leaves the collator last. This document will not be folded. During in-sertion into the envelope the documents of the set will be realigned.

The conditions are:• The feeder that supplies this upper document (BRE) is set to one

document per set (no multi feeding).• The document directly beneath this document must be at least

60 mm longer than the BRE.• The upper document must be longer than the set address fold.• The folding mode is either single fold or letter fold (so no Z-fold).• The upper document must be shorter than the envelope height.

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Background information:The BRE offset can be used for a BRE and an enclosure (card) in 1 set. The extra condition is that this enclosure is equal to or smaller than the set address fold and should be placed directly underneath the BRE in the set.

The whole BRE offset is based on friction between the documents in a set. Therefore, it is necessary to make use of these conditions to reduce the risk of poor transporting, folding and inserting.

In some cases the BRE option is automatically switched off if one or more of the above-mentioned conditions are not met, so it is safe to switch the BRE option on, unless this option will never be used.

4.3.2.4 Secure jobs

Use this menu to secure (i.e. lock) the selected job. This job can not be deleted and can not be changed in the job menu either. However, a locked job can still be copied into another job that can be modified.

4.3.2.5 Flap closer

Use this menu to adjust the timing of the activation of the sealing so-lenoid (So3) on a per-job basis. This function can be used to improve the sealing process. The timing has influence on the position of the filled envelope (with its flap fixed between two rollers) prior to being transported between the sealing rollers. This position can be adjust-ed between -10 and + 10 mm (with respect to the default envelope position).

4.3.3 Service Tests

4.3.3.1 Photocells

This machine uses so-called intelligent photocells: The currents of the photocell transmitters are adjusted in such a way that the no-pa-per output voltage of the photocell receiver is within a certain voltage range of the photocell receiver. In this way, a reasonable amount of dust on the photocell sensors can be compensated for. The control mechanism ensures that very reliable "paper" and "no paper" deci-sions are being made, based on the paper photocell condition.

The screens provide real-time information on the various paper pho-tocells. You also can see if the relevant photocell "sees" paper.

Before readjusting the photocells you must remove all paper from the


User interface

Release: 07/2006

machine and clean all the sensors (both transmitter and receiver!) of the photocells.

After the photocells have been adjusted, the percentages in the screens should be lower (if the cleaning advice was followed). If no paper is present, the photocell output voltage should have a value between 0.8 V and 1.5 V. A value below this voltage range indicates that the photocell is too dirty. A value above this voltage range may occur if after readjusting a photocell dust is removed. In both cases, the photocells must be adjusted.

If the photocell current percentage is below 75%, the message "OK" is shown. A percentage between 75% and 99% results in a "Clean" message. The photocell should be cleaned before resetting the pho-tocells. The message "Defect" is shown when the percentage is 99% or 100%

4.3.3.2 Digital inputs

The digital input screens show:• the real-time status of the three safety switches (MS1, MS2 and

MS3)• the two folder cam disks (SPH3 & PD3; SPH4 and PD4) • the two pulse discs (SPH1 for the main motor M1 and SPH2 for

the collator motor M2)

Real-time means that a change is reflected in the displayed status.

This allows you to easily check the correct operation of the three mi-croswitches. The folder cam discs can also be tested.

During testing, the relevant cam disc will move one half cycle, i.e. the cam disc status changes from "open" to "covered" or from "covered" to "open". After pressing two successive times on a test key the cam disc has performed a full cycle and returns to its original position.

Both pulse discs can also be tested. Press the Test key to test the pulse disc signal. Both the speed and the quality (duty cycle) will be tested. Detailed information is obtained via the minimum (Min.) and maximum (Max.) value. The speed range should be between 75% and 125%. The Pulse dist. (Duty cycle) value should between 50% and 150%. If this is the case the message 'Good' will be displayed. If this value is out of range, the message 'Bad' will be displayed.

The speed is checked by measuring the average pulse width and comparing it to the initial value. When the speed is much lower than the initial value, the mechanical load has to be checked. If it is higher, the pulse disc might be loose.

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The Pulse dist. (duty cycle) is measured of each pulse and the mini-mum and maximum values are shown. When a pulse (an indented area) is not detected (for example because of dust build up) the pulse distance will show a value of Min. 0% and/or Max. 200%.

4.3.3.3 Actuators tests

The actuator can be selected and activated. The motor runs as long as the test key is pressed. If the fingers solenoid is selected, the fin-gers move forward as soon as the test key is pressed. Only after re-leasing the test key the fingers will move back to their rest position. The eject rollers and closer solenoids will be activated and after a short time deactivated during one period of test key pressing.

During normal operation these three actuators are always activated for a very short time. This test reflects this situation. Testing the en-velope track clutch CL6 will result in switching on the motor M1, as well as activating the envelope track clutch.

Collator run in: Collator motor runs in the direction of the document stop position when activated.

Collator run out: Collator motor runs in the direction of the folder when activated.Folding pocket 1/2: The main motor M1 is switched on. The relevant fold pocket turns a half fold cycle. After two successive key presses, the initial position prior to entering this menu is reached.

Feeder clutches: The main motor M1 is switched on and the rele-vant feeder clutch is activated if the key is pressed. The feeder 3 clutch is only visible in the case of a 2½-station version of the ma-chine.

The MaxiFeederTM option is only available if the MaxiFeederTM is present. As long as the key is pressed, its motor will run.

4.3.3.4 Run in

This screen has a counter (with default value of 6000) that shows the number of process cycles that will be emulated, with no paper what-soever present in the machine. After pressing the Start/Stop key, the run in test will start. After each process cycle the counter decre-ments. The machine stops automatically if the counter value is zero.

You can set the counter to a value other than the default value 6000. If the counter value is 1000 or higher, increments are 1000 with a


User interface

Release: 07/2006

maximum value of 30000. if the counter value is lower than 1000, decrements are 100 with a minimum value of 10.

If some covers are removed (but not the safety covers!), you can watch the sequence of the various mechanical actions, which reflect the sequence of events during normal operation.

It is also highly recommended to perform the run in test without any documents in themachine. The timing of the actions for a simulated process cycle are fixed, so they are not based on parameters such as the document length. A run in test with documents present in the machine would only result in severe paper jamming.

4.3.3.5 DFC test

This menu gives information on the DFC unit output voltage of the two or three feeders. The values are real time. If no paper is present in a feeder the DFC voltage should be approximately 4.1 volt. If dur-ing the machine start a DFC unit does not "see" paper, the DFC volt-age should be about 9.9 volt.

The DFC voltage is lower if the DFC unit "sees" paper. The following rules apply:

• For 65 g/m² paper DFC voltage about 0.2 volt lower• For 80 g/m² paper DFC voltage about 0.25 volt lower• For 120 g/m² paper DFC voltage about 0.35 volt lower• For 160 g/m² paper DFC voltage about 0.5 volt lower

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Touch screen

Use the "Test touch screen" button to check if the touch screen is working correctly. A graphical object will be displayed on the screen at each point where the screen is touched. The screen can be touched with either a finger or a (non-scratching) pen.

If the area touched does not exactly correspond with the displayed object, the touch screen should be calibrated. To do this, use the "Calibrate touch screen" button.

4.3.4 Service counters

This menu allows you to read, set, or reset the service counters:• The "since last visit" counter can be reset to zero.• The "since installation" counter can be displayed.• The "next visit after" counter can be:

- incremented in 5000 steps to a maximum value of 6.000.000 steps.

- decremented in 5000 steps to a minimum of 5000 stepsA value under 5000 results in the value OFF.

• The "feeder" counters (1 through 3) can be reset to zero.• The "envelope hopper" counter can be reset to zero.

4.3.5 OMR

4.3.5.1 OMR code definition

This menu allows you to define the OMR-2 reading codes, providing that the machine has OMR enabled. One OMR code can be set for each machine. This code can be used for one or more jobs.

The following list shows all system options (customer dependant):• Start mark• Insert on• Divert mark (implemented as a stop mark) (FPi 4030 only)• Stop mark (FPi 4030 only)• Selective feed (FPi 4030 only)• Sequence check (FPi 4030 only)• Parity check• Safety mark• Line spacing

Choose between Yes and No (toggling function). The line spacing can be changed in steps of approximately 0,02 millimetre. The Lpi


User interface

Release: 07/2006

value reflects the number of lines per inch, the millimetre value is the distance between two successive marks.

4.3.5.2 Read-code test

Use this menu to test the OMR reading head (RH1) and, if neces-sary, to readjust the relevant OMR electronics.

The displayed test information is:• Mark quality (the quality of the marks: bad, good or very good)• Marks (the number of marks that have been read)• Gain (the gain of the amplifiers involved in the OMR electronics. The values are 1, 3, 5 or 7)Select "Adjust" to start testing the reading head.

The settings of the current job are used for this test. This implies that an OMR job must be selected, otherwise the text "Select a job with OMR" will appear. If the OMR codes on the paper used differ from the OMR codes for the current job, the number of marks that have been read are incorrect.

After selecting "Adjust", another menu appears. Information about the number of OMR test sheets to be placed in the upper feeder is first shown. Select "Start adjust" to start the OMR adjustment. The text "Adjusting…" appears. The end result will either be: • "Adjusting OK"• "Adjusting FAILED"

The current OMR job settings are used for this test. If this is not the case, the text "Select a job with OMR" appears. If readjustment of the OMR electronics was successful, "Save and exit" is displayed. Select "Save and exit" to return to the original OMR menu. This menu now shows the benefit of readjusting the OMR electronics.

Select "Show marks" to display a graphical representation of the marks that had been read (oscilloscope function). The information shown is derived from the most recently read document.The information screen shows the time-dependant OMR output volt-age and the reading window. See following figure.

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The start of the window is represented by a vertical line, the end of the reading window is also represented by a vertical line. In between the marks should be given where the position of the marks related to the window position is also giving some information, i.e. when the first mark is very close to the opening of the window; this could mean that the window position is programmed wrong.

The upper horizontal dotted line represents the noise level, i.e. the white level. The lower horizontal dotted line represents the level be-low which a mark (i.e. detection level) has been detected. The detec-tion level is determined when the adjustment procedure is performed. The detection level is 60% of the top level. A mark is de-tected as an OMR-mark when more than 5 digital samples consecu-tively are below the detection level.

The numbers 1 through 6 indicate where a mark is expected. The distance between the numbers is exactly the same as the pro-grammed line spacing. Select the arrows to scroll to the left or the right. Scrolling to the right shows a later point in time; scrolling to the left shows an earlier situation.

Select the info. key to display the information screen. This screen shows additionalOMR-related information. This information is based on the last read document and the job settings (OMR code type etc.). The displayed information is what is interpreted from the read OMR code.

Select the "Test" key to shows the mark quality and the number of read marks from the last processed document. Also the gain of the OMR amplifier is shown.

ESCAPE

SHOW MARKS

1

63

128

1 32


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The mark quality is either:

Bad: Mark amplitude < 0.6 VGood: Mark amplitude between 0.6 V and 1.5 VVery good: Mark amplitude higher than 1.5 V

Select the info. key to display the information screen. This screen shows additionalOMR-related information. This information is based on the last read document and the job settings (OMR code type etc.). The displayed information is what is interpreted from the read OMR code.

4.3.6 Diagnostics

4.3.6.1 Start test

This test checks if all motors, clutches and sensors are correctly con-nected. The system test derives the status of the actuators and clutches by briefly activating the actuators and then measuring the current. At the end of the test the photocells will be re-calibrated.

The individual functioning of sensors (e.g. photocells) and clutches (e.g. timing) is not checked. This must be done in the special Photo-cell, Digital inputs and Actuator test menus.

Before starting this test make sure:

• all paper is removed from the system• all covers are closed

4.3.6.2 Error counters

This menu displays the last 40 errors that occurred. Select "clear" to clear all error messages.

4.3.6.3 Last error list

This menu displays a list with the 40 most occurring errors. Select "clear" to clear all error messages.

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4.3.7 Online service

4.3.7.1 Server port

Use this menu to enter:• the IP address of the server• the server port of the server

4.3.7.2 Reset CB data

Use this menu to clear the data on the communication board, and to reset the status of the communication board to "undeclared".

Once the communication board has been reset, it can be used in an-other system. As soon as the communication board is installed in an-other system (i.e. during a board replacement), it will be automatically reset.

4.3.7.3 Test CB

Select Test CB to check the following:• the serial port• the modem• the real time clock

Fail or Pass will be displayed for each item depending on the result of the test.

Serial portUse this option to check if the RS-232 serial port and cable are work-ing correctly. Connect the special test plug, and then select Test CB. The special RS-232 test plug has pins 2 and 3 jumpered together. During the test a send, response is sent through the cable and plug (Rx, Tx).

ModemUse this option to detect if:• the modem is present.• there is a dial tone.

Real time clockUse this option to check if:• the communications board has a battery, and the battery is work-

ing correctly.• the communications board clock is working correctly.


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4.3.8 Remove blockage

During system start-up, the serial number stored on the main board is compared to the original serial number in the ID-tag. After a main board or ID-tag has been replaced, the machine may have lost it's identity, backup counter, and enabled features. This will block the normal operation of the machine.

The machine will show error INS: 186 "Illegal configuration" during machine start-up. The user can still access all menus, but the ma-chine will be blocked from running jobs or Fill & Start. The blockage can only be removed if a service technician accesses the password protected service menu and confirms that the ID-tag or main board have been replaced.To do this: from the "Main menu" select "Job menu" (and enter the PIN code), and then select "Remove blockage".Main board replacementAfter a main board replacement, No will be answered. The identity, backup counter and enabled features will be restored from the ID-tag.

ID tag replacementAfter an ID-tag replacement (factory prepared), Yes will be an-swered. As a second question, you will be asked to enter the new to-tal counter of this inserter. A backup of this counter will be copied to the new ID-tag.

4.3.9 Sealing on franking machine (not yet available)

This option is only available if Insert‘n FrankTM is set to level 2 or 3. By default, sealing is disabled on the franking machine when an In-sert‘n FrankTM job is selected. This service menu option, allows you to ignore the sealing settings of the franking machine. A warning will be displayed each time the job is started on the inserter (INF:51).

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User interface

Page 4–16


The FPi 4030 inserting system

5 The FPi 4030 inserting system

Release: 07/2006

5.1 Transport, storage and installation

5.1.1 Transport

The system, including all accessories, is transported in one box. The box is attached onto a pallet. Handle the package with care.

Warning• Do not turn the box on its side.• Prevent the box from falling over.• Prevent the box from shaking.

NoteWhen shaking (during transport) is expected, follow this procedure:1. Remove the feed hoppers.2. Tighten the feeders.3. Secure the collator.

5.1.2 Unpacking and storage

UnpackingThe system is unpacked by the haulier. The packing material, includ-ing the pallet, is taken along. The unpacking instructions are illustrat-ed in the following figure.

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remove packing material

Page 5–2



Release: 07/2006

StorageThe system needs to be stored under the following conditions:

5.1.3 Installation

Storage temperature: 10 to 40 °C (50 to 104 °F)

Humidity: 30 to 80%

Warning• Only an approved installer is allowed to install the system.• Make sure that you are fully aware of all the safety aspects before you

install the system.

1 Connect the power cables. 2 Attach the feeder trays.

3 Check the feeder adjustments. 4 Attach the envelope tray (optional).

5 Check the envelope adjustments.

A

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Page 5–4

6 Fill the water reservoir.

7 Moisten the brushes.

8 Switch the system on. 9 Check the localization menu (service menu/system settings/

localisation) for the Sales Organisation and country specific details.

10 Perform a Fill & Start job to check the correctness of the- Fold mm (or adjust the folder offset in the service menu).- Flap closer quality (or adjust the flap closer offset in the

service menu). 11 Configure alternative options based upon the requirements. See

Section 7 “Upgrading and installing accessories”.



Release: 07/2006

5.2 Mechanical description

5.2.1 (Dis)assembly - Covers and plates

Right-hand side cover

LH

RH

21

To disassemble the right-hand side cover: 1 Open the upper unit by lifting the hand grip (2). 2 Remove (loosen) the six screws of the right-hand side cover (1). 3 To remove the cover, turn and move as shown in the figure.

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Left-hand side cover

1

234

LH

RH

To open the left-hand side: 1 Open the upper unit (1) and the hinged cover (4). 2 Remove (loosen) the two screws of the Left-hand side cover (2). 3 Remove the two screws and loosen one screw of the inner cover

(3).



Release: 07/2006

Top cover feeders, covers collator area, power supply cover

1

2

3

LH

RH

4

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Page 5–8

1 Remove the top cover feeders (1), the covers of the collator area (2), and the power supply cover (3).

2 Remove the water tray. 3 Place the machine carefully at the right hand side on a felt path. 4 Slacken the two screws of the bottom plate (4) and remove the

bottom plate.



Release: 07/2006

Covers upper unit

To easily access the interior, open the covers in the following order:

LH

RH

1

2

3

4

5

1 Vertical transport cover (4) 2 Top covers (1, 2, and 3) 3 Loc cover (5)

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5.2.2 (Dis)assembly - Electrical components

NoteWhen a board is installed and the system is switched on, you must check if the correct software is installed. If the correct software is installed, the machine will start to synchronize with the ID-tag (99.45.04). See Section 3.5.4 “The ID-tag (99.45.04)”. If the board is new to the system, the error message INS: 186 will be displayed, which indicates that the serial number in the ID-tag (99.45.04) does not match the serial number in the FRAM of the main board. This will prevent the machine from working. Before you can use the system, you will have to remove the blockage. See Section 4.3.8 “Remove blockage”.

WarningPotential hazard may exist to electronic hardware in conditions with static electricity. It is advised that, when handling electronic parts, an earth connect-ed wrist band is used in order to be permanently discharged from static elec-tricity.



Release: 07/2006

Main board

1 2LH

To disassemble the main board: 1 Disconnect the wiring to the main board (1). 2 Remove the screw (2). 3 Lock washer and spacer. 4 Carefully pull the main board from the board holders as shown.

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ID-TagOrdering and installing new ID tag:• When the ID tag fails, the system can continue running without

using OMR or Insert‘n FrankTM features. At start up, and at each 100 cycles, the operator will see an error message "ID/Option memory update fails" or "ID memory not detected".

• Place an order for a new id-tag for a specific serial number.• NTBV will send you a replacement id-tag containing the same

features as known by NTBV for that serial number.• As the old id-tag may contain valuable features, double check the

provided features with your own administration.• When correct, make sure you destroy the old id-tag (id-tags may

never be used on other systems!).• At the installation of the new id-tag, the system will go into "block-

age". In the service menu you can de-block the system and set the counter.



Release: 07/2006

Display board (FPi 4030)

24

3

5 6

1

LH

Before removing the display (2) or the display board (3), the com-plete display bracket must be removed from the system. 1 Remove the top cover (1). 2 Remove the two screws that hold the bracket to the system. 3 Disconnect the display cable (4). 4 Withdraw the display bracket carefully. 5 Disconnect the wiring (5 and 6) so that the display board can be

removed. 6 Carefully remove the display board.

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32

56

LH

To remove the display: 1 Remove the four screws (3) which secure the display (2) to the

mounting bracket display (6). 2 Withdraw the display (2) carefully.

NoteConnect the wiring before replacing the display. Be sure to replace the four spacers (5).



Release: 07/2006

5.2.3 (Dis)assembly - Feeder modules and vertical transport right-hand

The feeders, the vertical transport and the fold unit are driven by belt (4) and the accompanying pulleys, gears, etcetera as shown in the following figure.When the machine is running the four transportation axles are con-tinuously driven by the belts (4, 5 and 6). The three upper transpor-tation axles are equipped with a clutch and a pulley. When, for example, the clutch (2) is activated, the accompanying feeder is driv-en by pulley (3) and belt (1) and a document is fed to the vertical transport track.

1

2

3

6

5

4

RH

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Drive mechanism right-hand - Belts and pulleys

Belt 4

5

RH

2

3

4

1

1 Slacken the two screws of the belt tensioner (5). 2 Shift the belt tensioner downwards. 3 Remove belt 4 from the pulleys.

Pulley 1 1 Loosen the main belt, PJ belt and drive belt inserter. 2 Remove the spring clip. 3 Slide the main pulley off the axle.

Pulleys 2 and 3Pulleys 2 and 3 are "snapped" to their cyl. pins. They can be re-moved by pulling them off the axle.



Release: 07/2006

1 2 3 4 5

12 13 14

RH

678

Belt 4 1 Slacken the hexagonal head screw of the belt tensioner (1). 2 Remove belt 4 from the pulleys.

Belt 7Belt 7 is removed in the same way as belt 4.

Pulleys 3, 5 and 6Pulleys 3, 5 and 6 are "snapped" to their cyl. pins. They can be re-moved by pulling them off the axle.

Pulley 8 1 Remove the hexagonal head screw of the belt tensioner (2). 2 Withdraw the tensioner. 3 Slide the pulley 5 from the axle. 4 Remove the cyl. pins from the axle. 5 Slide pulley 8 off the axle.

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Drive mechanism left-hand

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Belt 1 Unhook the tension spring (2) from the inside frame. 2 Remove belt 1 from pulley 3.

Clutch and Pulley 1 Disconnect the wiring of the clutch. 2 Remove the spring clip (6). 3 Slide the clutch (5), the disc (4), and the pulley (3) off the axle.



Release: 07/2006

5.2.4 (Dis)assembly - Feeders

All the feeders are provided with dividable drive axles. Removal of the complete feeders: 1 Remove the hoppers. 2 Remove the extension part of the drive axle (9, refer to the

following figure). Take care that it is a left side screw-threaded axle end. Each feeder can now be removed separately.

3 Fix the main axle by a pin on one of the holes.

At the right-hand side the feeders are equipped with a tension spring for proper lifting of the feeder. The tension spring is hooked on a mounting bracket at the frame.

NoteDo not remove the mounting bracket or exchange the tension spring from one to another feeder. Each spring is specially adjusted from the factory by positioning the mounting bracket.

Top feeder (feeder 3)

7 10 6 5 4 3 2

9

18

LH

RH

To loosen the top feeder: 1 Unhook the tension spring (7) from the screw (8) (on the right-

hand side of the feeder). 2 Disconnect the wiring of the feeder. 3 Cut the wire straps. 4 Remove the wiring from the left-hand inside frame.

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5 Remove the spring clip (1), clutch (2), belt (4), and pulley (3) of the top transportation axle.

6 Unhook the tension springs (5) from the inside frame. 7 Remove the screw of the left-hand and right-hand hinge pin (6)

of the top feeder. 8 Remove the top transportation axle (10) by moving it in the right-

hand direction.

B

A

LH

RH

To remove the feeder: 1 Move the feeder a bit downstream as indicated (A). 2 Lift the right-hand side of the feeder first. 3 Remove the feeder from the machine (B).

NoteBe careful when replacing feeder 3, the hinge pin at the right-hand side is locking the ball bearing.



Release: 07/2006

Middle feeder (feeder 2)

1 2 3 4 5 6 7 8

11 10 9RH LH

To loosen the middle feeder: 1 Unhook the tension spring (2) from the screw (1) (on the right-

hand side of the feeder). 2 Disconnect the wiring of the feeder. 3 Cut the wire straps. 4 Remove the wiring from the left-hand inside frame. 5 Remove the spring clip, clutch (9), belt, and pulley of the middle

transportation axle. (Remove axle to the right-hand side.) 6 Unhook the tension spring (10) from the inside frame. 7 Remove two hexagonal heads. 8 Remove the guide plate (5). 9 Remove the screw of the left-hand and right-hand side hinge pin

(11) of the middle feeder.

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Page 5–22

RH LH

�

�

To remove the middle feeder: 1 Move the feeder a bit downstream (A). 2 Remove the feeder by turning it out of the machine as indicated

(B).

NoteBe careful when replacing feeder 2, the hinge pin at the RH side is locking the ball bearing.



Release: 07/2006

Lower feeder (feeder 1)

To loosen the lower feeder:

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RH

LH

1 Unhook the tension spring (2) from the screw (1) (on the right-hand side of the feeder).

2 Disconnect the wiring of the feeder. 3 Cut the wire straps. 4 Remove the wiring from the left-hand inside frame. 5 Remove the spring clip (7), clutch (6), belt (8), and pulley (5) of

the lower transportation axle. (Remove axle to the right-hand side.)

6 Unhook the tension spring (4) from the inside frame. 7 Remove the two screws of the left-hand and right-hand side

hinge pin (3) of the lower feeder.

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Page 5–24

�

�RH LH

To remove the lower feeder: 1 Move the feeder as far as possible downstream (A). 2 Remove the feeder by turning it out of the machine as indicated

(B).

NoteBe careful when replacing feeder 1, the hinge pin at the RH side is locking the ball bearing.



Release: 07/2006

Automatic separation feeder (with daily mail)This section describes the replacement of the rollers and pulleys of the feeder. For several replacements it is necessary to remove some covers above or below the feeders. The removal of these covers is shown in the following figure.

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RHLH

To remove cover 1 to 4: 1 Remove the screws on the right-hand side. To remove cover 1,

it’s necessary to remove the top cover first (see Section “Top cover feeders, covers collator area, power supply cover” on page 5–7).

2 Pull cover 1, 2 and 3 backwards on the right-hand side and pull it out on the left-hand side.

3 Loosen the screws (6) at cover 5. 4 Remove the cover. 5 Pull cover 4 backwards on the right-hand side. 6 Pull it out on the left-hand side.

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Rubber paper pullers

A

D

C

B

1 2 3 4

LH

RH

To remove the rubber paper pullers: 1 Remove the feed axle assy. (2) in the right-hand side direction

(A) until the left-hand side is clear from the axle (1). 2 Tilt the axle assy. (2) at the left-hand side (B) and withdraw the

right-hand side off the axle from the hole in the feeder frame. 3 Remove the axle assy. as indicated (C). 4 Hold the plastic cover (3) in place with one hand and push firmly

against the rubber paper puller as indicated (D). 5 Rotate the axle 180 degrees and push again. Repeat the

rotating and pushing until the paper puller can be pulled off the axle.

NoteEnsure on replacement that the plastic cover is replaced below the ridge (3) on the paper guide and that the feeder assy. is correctly fitted onto the axle. Ensure that the belt runs across the pulleys.



Release: 07/2006

Pulley of paper puller axle

To remove the pulley of the paper puller axle:

LH

RH

1

1 Remove the feed axle assy. as described in Section “Rubber paper pullers” on page 5–26.

2 Remove the axle from the plastic cover. 3 Push the rubber paper puller off the axle. 4 Remove the spring clip, the washer and the bearing. 5 Push the pulley assy. to the left to release it from the cyl. pin. 6 Remove the cyl. pin. 7 Slide the pulley assy. off the axle.

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Upper separation roller

NoteThe feeder unit does not need to be removed for replacing separation rollers.

To remove the upper separation roller:

Grease 1

2

Push A

LH

RH

1 Remove the feed axle assy. as described in Section “Rubber paper pullers” on page 5–26.

2 Click the plastic cover (2) off the axle (A). 3 Remove it with the belt and the paper pulleys from the feed axle. 4 Remove the grease from the left hand side of the feed axle with

some alcohol. 5 Push the feed roller (1) to the left hand side off the axle as

indicated. 6 Rotate the axle 180 degrees and push again. 7 Repeat the rotating and pushing until the feed roller can be

pulled off the axle.

NoteBefore replacing the feed roller, ensure that the axle is free of grease. After replacing the feed roller, put some grease Molykote PG 65 on the plastic cover (2) as shown in this figure. Replace the plastic cover with the belt and the rollers.



Release: 07/2006

Lower separation roller

NoteThe feeder unit does not need to be removed for replacing separation rollers.

To remove the lower separation roller:

1 2

A

B

LH

RH

1 Remove cover 3 as described in Section “Automatic separation feeder (with daily mail)” on page 5–25.

2 Move the separator axle assy. (2) in the right-hand side direction (A) until the left-hand side is clear from the hinge plate (1).

3 Move the axle assy. (2) downwards side and withdraw the right-hand side of the axle from the hole in the feeder frame.

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4 Slide the roller (1) off the axle assy. (2) as shown in the following figure.

1 2

LH

RH

NoteBefore replacing the feed roller, ensure that the axle is free of grease.

GearsFor the removal of the gears at the left-hand side of the feeder it is not necessary to remove the feeder from the machine.The gear 48T can be removed after the extension axle with the pulley etc. has been removed. 1 Remove the spring clip securing the gear 64T. 2 Lift the feeder. 3 Slide the gear 64T off the axle.



Release: 07/2006

5.2.5 (Dis)assembly - Vertical transport

LH

RH

To get access to several parts of the vertical transport track, remove the vertical transport cover as described in Section “Covers upper unit” on page 5–9.

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5.2.6 (Dis)assembly - Collating area

1

LH

The parts which are described in this section are located in the upper arm of the collating area. It is recommended to remove the complete collating arm. 1 Remove the collator area covers as described in Section “Top

cover feeders, covers collator area, power supply cover” on page 5–7.

2 Disconnect the wiring of the collator motor.



Release: 07/2006

3 Loosen the set screw (7) on the bush (6) as shown in the following figure.

LH

7 6

4 Pull the motor out of the frame. 5 Support the collating arm. 6 Remove the screws (1) as shown in the figure above (two at the

left-hand side and two at the right-hand side). 7 Carefully remove the collating arm.

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Page 5–34

Collator stops (FPi 4030 only)

To remove the collator stop motor:

LH

RH4

5

3 2 1

5

1 Remove the plate with clips attached (1). 2 Remove the moving arm (2). 3 Remove the gear wheel (3). 4 Disconnect the collator stop motor wiring. 5 Remove the two screws (4) that hold the collator stop motor in

place, and carefully remove the motor (5).



Release: 07/2006

Belts

Transportation belts

LH

RH

7 6

1345 2

9 108

The transportation belts are only available as a set. If a belt is worn, all the belts should be replaced. 1 Remove roller 1 from the axle. 2 Slide the axle to the left-hand side out of the bearings. Take care

of the tensioner (2), it is spring loaded. 3 Remove the tensioner (2). 4 Remove the plate (3). 5 Remove the axles (4 and 5).The middle transportation belt can now be replaced.

Guide rollersThe guide rollers (8 and 10) are spring loaded. 1 Remove the accompanying spring clips and washers. 2 Slide the guide rollers off the axles. 3 Remove the screw of the axle of the guide roller (9). 4 Slide the axle to the left-hand side. 5 Remove the spring clip at the right-hand side of the guide roller. 6 Slide the roller off the axle.

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Page 5–36

5.2.7 (Dis)assembly - Folder

Right-hand drive mechanismLower folder section

4 3 2 1

RH

Belts:The removal of the drive belt (1) is described in Section “Drive mechanism right-hand - Belts and pulleys” on page 5–16.

Pulleys: 1 Remove the drive belt (1). 2 Remove the accompanying spring clip. 3 Remove the clamping ring. 4 Slide pulley 2 and 3 off the axles.



Release: 07/2006

Gears:The gears, number 4 (picture on page 5–36) and number 1 (following picture), can easily be slid off the axles. Take care of the cyl. pins when removing the gears.

RH

1

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Page 5–38

Upper folder section

RH

1

2

3

45

6

10 9 8 7

Belts: 1 Slacken the two screws (2) of the belt tensioner (1). 2 Remove the belt (5) from the pulleys (3 and 6).

Pulleys: 1 Remove the belt (5) as described in the previous section. 2 Remove the spring clip and the washers of the pulley (3). 3 Slide the pulley off the axle. 4 Slacken the set screw (4) of the pulley (6). 5 Slide the pulley off the axle.



Release: 07/2006

Gears 8 and 10: 1 Remove the spring clip, clamping ring and washers. 2 Remove the gears (8 and 10). When removing gear 8, take care

of the cyl. pin.

Gear 9: 1 Remove the belt (5). 2 Remove the pulley (6). 3 Remove the spacer (7). 4 Remove gear 9.

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Page 5–40

Left-hand drive mechanismGears

��

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To remove the gears of the lower folder section (1 to 5) at the left-hand side of the machine: 1 Remove the circuit board. 2 Remove the spring clips, clamping rings and washers. Take

care of the cyl. pin of the gears 1, 3 and 5 and the spacers of the gears 2 and 4.

3 Remove the gears (1 to 5).



Release: 07/2006

Fold mechanism

RH

1 2 3 4 5 6 7 8 9

11

10

12

13

14

151617

The fold plates (1 and 5) are driven via the curved gears (6, four in total) and two gears (3), activated by the two clutches (2) on the drive axle (4).

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Page 5–42

Gears 32T, drive axle 1 Remove the belt (13), pulleys (12 and 14) and freewheel clutch

(11). 2 Remove the locking plate (10) securing the bearing of the drive

axle (4).

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3 Carefully move the axle (4) to the right-hand side until the bearing clears the frame.

4 Carefully lift the axle assembly as far upwards as possible. Take care of the wiring of the clutches on the axle and the plastic bearing on the left-hand side.

5 Remove the bearing, spacer, washers and the spring clip of the left-hand side of the drive axle assembly.

6 Slide the gear (1) off the axle.

To remove the gear (4) and clutches (2 and 3): 1 Cut the wire straps at the connectors of the clutches. 2 Slide the clutch (2) to the left-hand side of the axle. Take care of

the cyl. pin of the clutch. 3 Remove all the components between the clutches, including the

cyl. pin of the clutch (3). 4 Slide the clutch (3) to the left-hand side off the axle. 5 Remove the gear (4) from the drive axle.

NoteEnsure on replacement to secure the wiring of the clutches again and that both clutches are retained by the locking plate. Also ensure that the clutches clockwise and counterclockwise are placed in the proper position.



Release: 07/2006

Curved folder gears 1 Remove the drive axle assembly as described in Section

“Gears 32T, drive axle” on page 5–41 (refer to the picture on the same page).

2 Remove the bearings (9) from the axles (6). 3 Remove the brake discs (15, spring loaded), the springs, the

brake strip (16) and the bearings (17) from the axles (8).

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4 Remove the levers for the flap actuators, the bearings, etc. (1 up to 6) from the axles (12). Pin 6 has to be loosened by a set screw, to be accessed at axle end (12).

5 Remove the brackets (7) with the sensors. 6 Remove the brake discs with the bearings (20 up to 22) from the

axles (13). 7 Remove the screws at the left and right-hand side of the guide

plate (9)

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Page 5–44

8 Unhook the guide plate and remove it. 9 Remove the screws at the left and right-hand side by which the

brackets (10) are mounted to the upper frames. 10 Carefully lift each complete fold assembly upwards and

withdraw it.First curved folder gears

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Release: 07/2006

To remove the curved gears: 1 Remove the two screws (6). 2 Slide both hinge plates (5 and 7) together with the fold plate (4)

off the axle. 3 Pull the curved gears (2 and 8) off the axle. Second curved folder gearsRefer to the figure on page 5–44. 1 Remove the hinge plates (15 and 17) in the same way as

described previously. 2 Pull the curved gears (9 and 10) off the axle.

NoteEnsure on replacement that the curved gears and the curved discs are replaced correctly onto the axle (refer to the following figure). Secure the wiring of the clutches again. The right hand curved gear is marked with an "R" and the left-hand curved gear is marked with an "L".

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NoteAfter replacing and securing the complete fold assembly, check the adjustment of the paper guides (3 and 11, refer to the figure on page 5–44). See Section “Paper guide” on page 5–96.

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Page 5–46

RollersInput rollersRemove the drive belt as described in Section “Drive mechanism right-hand - Belts and pulleys” on page 5–16.

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To remove the input rollers: 1 Remove the pulley, the gears of the upper input rollers (1) and

the gears of the lower input rollers (2) as described in Section “Right-hand drive mechanism” on page 5–36.

2 Remove the bearing locking plate (3).



Release: 07/2006

� � � � �

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3 Remove the gear 7 of the lower input roller (6). 4 Remove the bearing locking plate (5). 5 Remove the guide strip (4) and the guide bracket below it. 6 Move the upper input roller (2) to the right-hand side until the

left-hand bearing is free of the left-hand inside frame. 7 Lift the left-hand side of the roller upwards and withdraw the

roller out of the right-hand inside frame. 8 Move the lower input roller (6) to the right-hand side until the left-

hand bearing is free of the left-hand inside frame. 9 Lift the left-hand side of the roller upwards and withdraw the

roller out of the right-hand inside frame.

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Page 5–48

Lower fold rollers 1 Remove the gears (8, refer to the previous figure).

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2 Loosen the two hexagonal head screws (3). 3 Push down the solenoid (4) to get access to the screw (2). 4 Remove the screws (2). 5 Remove the bearing plate (1). 6 Move the roller to the right-hand side until the left-hand bearing

is free of the left-hand inside frame. 7 Lift the left-hand side of the roller upwards and withdraw the

roller out of the right-hand inside frame.

NoteAfter replacing the lower fold rollers, check the adjustment of the solenoid. See Section “Solenoids” on page 5–97.



Release: 07/2006

Upper fold rollers

�� LHRH

To remove the upper fold rollers: 1 Remove the belt with the pulley (5) and the three gears (4) at the

right-hand side. 2 Remove the guide strip (2). This is necessary for the removal of

the first fold roller. 3 Remove the bearing locking plates (3) on both sides. 4 Move roller 1 to the right-hand side until the left-hand bearing is

free of the left-hand frame. 5 Move the left-hand side of the roller downwards and withdraw

the roller out of the right-hand frame.

NoteFor belt adjustments, see Section “Drive belt upper folder section”. page 5–95.

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Page 5–50

5.2.8 (Dis)assembly - Main drive mechanism inserter

12345678

RH

The main motor 8 provides the mechanical power to the FPi 4030, with exception of the collating area and the collator stops.



Release: 07/2006

BeltsPJ-beltFor removal of the PJ-belt (2): 1 Disassemble the main drive belt for the feeder and folder

section. See Section “Drive mechanism right-hand - Belts and pulleys” on page 5–16.

2 Loosen the two hexagonal head screws (4) of the tensioner (5). 3 Remove the belt (2) from the main pulley (1) and the motor

pulley (3).

Drive belt inserter

RH

1 2 3 4

7891011121314

5

6

All moving components of the inserter part are driven by belt 10. To remove belt 10: 1 Loosen the two hexagonal head screws of the tensioner (1). 2 Remove the belt from the pulleys.

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Item number: 51.0067.1001.00 Page 5–51



Page 5–52

Belt envelope feed

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To remove the belt envelope feed: 1 Remove the support plate (11) by which the intermediate axle

(13) is supported. Take care of the bearings and the washers. 2 Remove the belt (5) from the pulley on the intermediate axle and

from the pulley on the envelope feed axle (3).



Release: 07/2006

PulleysRefer to the figure on page 5–51.

Pulleys 5 and 9 1 Remove the spring clips of the pulleys (5 and 9). 2 Remove the pulleys (5 and 9).

Pulley 11 1 Remove the main pulley (refer to Section “Drive mechanism

right-hand - Belts and pulleys” on page 5–16). 2 Remove the pulley (11).

Pulley 8 1 Remove the mounting plate (6) with the adjustment plate and

the pulse disc sensor. 2 Remove the pulse disc (7). 3 Slide the pulley (8) off the axle. Take care of the spacer.

NoteAfter replacement of the pulse disc sensor be sure that it clears the pulse disc on both sides.

Refer to the figure on page 5–52.

Pulley 9 1 Remove the belt (5) as described in . 2 Remove the accompanying spring clip and washer of the pulley

(9). 3 Slide the pulley (9) of the envelope feed axle (3).

Pulley 14 1 Remove the bearings, washers and gears from the intermediate

axle (13). 2 Tap the tension pin from the intermediate axle. 3 Slide the pulley (14) off the axle.

GearsRefer to the figure on page 5–51.

Gears 3 (sealing rollers) 1 Remove the pulley (5). 2 Remove the spring clips and washers. 3 Slide the gears (3) off the axles.

Gear 2The gear (2) is mounted to the axle by a tension pin. To remove the gear (2):

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Item number: 51.0067.1001.00 Page 5–53



Page 5–54

1 Remove the tension springs of the bearings of the axle. 2 Remove the spring clip with washer and bearing at the left-hand

side of the axle. 3 Slide the two rollers to the right-hand side. 4 Remove the cyl. pin from the axle. 5 Slide the axle with the gear (2) to the right-hand side out of the

right-hand inside frame. 6 Tap the tension pin to remove the gear (2).

Gear 4The gear (4) is mounted to the pulse disc axle (14) by a tension pin. To remove the gear (4): 1 Remove the pulse disc (7) and the pulley (8). 2 Remove the spring clip at the left-hand side of the axle. 3 Slacken the set screws of the two rollers. 4 Remove the locking plate (13). 5 Slide the pulse disc axle (14) to the right-hand side out of the

right-hand inside frame. While doing this: remove the bearing, the washer, and the two rollers.

6 Tap the tension pin. 7 Dissemble the gear.

Gear 12 1 Removal of the pulley (9) 2 Slide the gear (12) off the axle.

Refer to the figure on page 5–52.

Gears 8, 10, 15, 16, 18, 20 and 22 1 Remove the spring clips and washers. 2 Remove the gears (8, 10, 15, 16, 18, 20 and 22).

Gear 21 1 Remove the nuts. Take care of the tension spring. 2 Slide all the parts of the brake rod. 3 Remove the gear (21).

For adjustment of the friction brake, see Section “Friction brake” on page 5–100.

Gear 6 1 Remove the gear (8). 2 Dissemble the clutch (7). 3 Remove the support plate (11). 4 Disconnect the wiring of the clutch. 5 Slide the clutch off the axle. 6 Remove gear 6.



Release: 07/2006

Gears 4 and 12 1 Remove the support plate (11) to free the intermediate axle (13)

with its components. 2 Remove the bearings, washers and spring clip from the axle. 3 Slide the gears (4 and 12) from the axle.

Gear 17 1 Remove the insert table to get access to the transportation axle. 2 Remove the spring clip, washer and bearing at the left-side of

the transportation axle (2). 3 Move the axle a little to the right-hand side. 4 Slide the gear (17) to the left-hand side. 5 Remove the cyl. pin. 6 Slide the gear (17) off the axle.

Gear 19The gear (19) is mounted to the transportation axle (1) by a tension pin. To remove this gear: 1 Remove the insert table. 2 Remove the spring clip, washer and bearing from the left-hand

side of the axle. 3 Slide the rollers to the right-hand side to remove the cyl. pins. 4 Slide the axle to the right-hand side out of the right-hand inside

frame. Take care of the two rollers. 5 Tap the tension pin. 6 Remove the gear (19) from the axle.

ClutchesSlip clutch envelope feed axleRefer to the figure on page 5–52. 1 Remove the metal ring of the pulley (9). 2 Slide the belt (5) of the pulley (9). 3 Remove the pulley from the axle. 4 Slide the slip clutch off the axle.

Clutch CWWhen the machine is switched on the gear (6) it is constantly driven. By activating the clutch (7) all the gears shown in the figure on page 5–52 and the accompanying axles and rollers of the envelope feed and envelope track will be driven. So to feed, open and place an en-velope on the insert table the clutch (7) is activated.To remove the clutch (7): 1 Remove the support plate (11) and the gear (8). 2 Disconnect the wiring of the clutch. 3 Slide the clutch (7) off the axle.

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Page 5–56

Power supply assy. and main motor (M2)

NoteThe main fuse can be replaced without removal of the covers.In the switch mode power supply (6) an extra fuse is present.

Power supply assy.

2

1

3

LH

To remove the power supply assy.: 1 Remove the main lead. 2 Remove the power supply cover (2). 3 Disconnect all wiring. 4 Cut the wire straps.



Release: 07/2006

45467 7

LH

5 Remove the two countersunk head screws (1) and the two round head screws (2) securing the power supply assy.

6 Pull the power supply assy. out of the machine.

NoteWhen replacing the power supply assy., ensure that the guide plates 1 (refer to the figure on page 5–56) are fitted correctly in the guide rollers. Also take care to fit the microswitch correctly and ensure the correct functioning.

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Page 5–58

Main motor M2

To remove the main motor:

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RH

1 Release the belt tensioner (5) 2 Remove the belt (2). 3 Remove the bottom plate of the machine. 4 Remove the four screws (6) and the washers (7). 5 Withdraw the motor (8) from the machine. Take care of the

wiring.

NoteFor belt adjustment, see Section “Main drive PJ-belt” on page 5–91, and Section “Main drive belt inserter” on page 5–93.



Release: 07/2006

5.2.9 (Dis)assembly - Envelope feed

HopperO-rings

To remove the O-rings:

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1 Move the side guides to the widest position. 2 Remove the centre front plate (9). 3 Remove the three screws (1) at the left-hand side and the three

screws (11) at the right-hand side of the hopper assembly (10). 4 Withdraw the hopper assembly (10) from the machine. 5 Remove the pulley (13) and slip clutch (12) as described in

Section “Pulleys” on page 5–53. 6 Remove the spring clips, washers, and bearings from the

envelope feed axle (5). 7 Remove the axle from the machine. 8 Slide the O-rings (7) from the joggers (6).

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Item number: 51.0067.1001.00 Page 5–59



Page 5–60

Separation roller

NoteBefore removing the separation roller, first check the adjustment procedure as described in Section “Separation roller” on page 5–99.

Refer to the figure on page 5–59. 1 Remove the centre front plate and the hopper assembly as

described in the previous paragraph. 2 Slacken the two screws (3) and remove the separation spring

(2) with the separation roller. 3 Remove the separation axle with roller from the separation

spring. 4 Slacken the set screw of the separation roller (4). 5 Slide it off the separation axle.

Feed rollerRefer to the figure on page 5–59. 1 Remove the feed axle as described in Section “O-rings” on

page 5–59. 2 Remove a jogger from the envelope feed axle. 3 Slacken the set screw from the feed roller (8). 4 Slide it off the axle.

NoteOn replacement of the joggers and/or feed roller, position the feed roller in the middle of the shaft and the removed joggers between the "forks" of the side guide. Take care to reassemble the rings between fork and jogger. Ensure that the set screws of the feed roller are tightened onto the groove of the feed shaft.

NoteFor adjustments, see Section “Separation roller” on page 5–99.



Release: 07/2006

Envelope trackLower rollers

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1 Remove the bottom plate. 2 Remove the spring clip, washer and bearing (spring loaded)

from the axle of the first set of the rollers (13). 3 Move the axle to the left-hand side to free the cyl. pins. 4 Remove the cyl. pins. 5 Lift the axle and slide the rollers off the axle. Take care of the

pressure spring of the bearings.

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Item number: 51.0067.1001.00 Page 5–61



Page 5–62

NoteRemove the second set of rollers (12) in the same way.Remove the inner two rollers in the same way.To remove the third set of rollers (11), first remove the outer two rollers.

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6 Remove the flap scraper (21). 7 Remove the pressure springs of the bearings of the fourth set of

rollers (19). 8 Slide the rollers to the left-hand side to remove the cyl. pin. 9 Remove the spring clips. 10 Slide the axle to the right-hand side and remove the rollers (19)

from the axle.

NoteFor adjustments of the flap scraper, see Section “Flap scraper” on page 5–101.



Release: 07/2006

Upper rollersRefer to the figure on page 5–61. 1 Remove the insert table as described in Section 5.2.11

“(Dis)assembly - Envelope transport”" on page 5–73. 2 Slide the first set of rollers (5) off the axle (7). 3 Remove the cyl. pins (4). 4 Remove the spring clip (1), washer (2) and bearing (3) at the

left-hand side of the axle (7). 5 Slide the axle to the right-hand side. 6 Remove the rollers from the axle.

NoteRemove the second and third set of rollers in the same way.

Refer to the figure on page 5–62. 1 Remove the insert table to get access to the fourth set of rollers

of the envelope track. 2 Remove the fixing plate envelope track (8, figure on page 5–61)

to get more room. 3 Slide the rollers aside to remove the cyl. pins. 4 Remove the spring clip, washer and bearing at the left-hand

side of the axle. 5 Slide the axle to the left-hand side. 6 Remove the rollers from the axle.

Rubber roller Refer to the figure on page 5–62. 1 Remove the insert table and the transportation table (19). See

figure on page 5–73. 2 Slide the transportation table in the direction as indicated, over

the second fold roller. 3 Remove the knob (1) and the spring clips (5) of the rubber roller

(11). 4 Remove the gear at the right-hand side of the rubber roller as

described in Section “Gears” on page 5–53. 5 Slide the roller to left-hand side to free the right-hand side of the

rollers from the right-hand inside frame. Take care of the bearing.

6 Lift the right-hand side. 7 Withdraw the rubber roller from the machine.

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Page 5–64

Finger solenoid

RH

1 2 3 4

1 Remove the draw bar (3). 2 Remove the tension spring (4). 3 Disassemble the mounting bracket (2) with the solenoid (1). 4 Remove the solenoid (1) from the bracket (2).

NoteFor adjustments of the solenoid, see Section “Solenoids” on page 5–97.



Release: 07/2006

5.2.10 (Dis)assembly - Upper unit

Drive mechanismThe drive mechanism of the upper unit is located at the right-hand side of the machine.

1

2

3

4

5

6

7

8

9

10

LH

RH

Belt 1 Slide the belt (8) of the pulley (7). 2 Remove the belt from the pulley (10).

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Page 5–66

PulleysPulley 10: 1 Remove the spring clip of the pulley (10). 2 Slide the pulley (10) from the axle.

Pulley 7: 1 Remove the axle (5) completely. 2 Open the upper unit. 3 Remove the six screws by which the brake plate (2) is mounted

to the upper frames. Take in account the weight of the upper unit when removing the dampers.

4 Close the upper unit and remove the axle (1). 5 Move the brake plate (2) with assembled components carefully

aside. Take care of the wiring to the solenoid, the sensor and display.

6 Remove the plate (3). 7 Remove the spring clips of the axle (5). 8 Slide the rollers off the axle (5) aside. 9 Remove the two cyl. pins. 10 Slide the axle to the right-hand side out of the right-hand frame.

Take care of the rollers, washers and bearings. 11 Tap the tension pin of the gear (9). 12 Slide the gear off the axle. 13 Remove the pulley (7) from the axle.

GearsGear 9:See the previous section (pulley 7).

Gear 6: 1 Remove the brake plate as described in the previous section

(pulley 7). 2 Remove the spring clips of the axle (4). 3 Remove the cyl. pins of the rollers. 4 Slide the axle (4) to the right-hand side out of the frame. 5 Tap the tension pin of the gear (6). 6 Slide the gear (6) off the axle.



Release: 07/2006

Document inserting

1 2 3 4 5 6

789101112

LH

RH

Rollers 1 Remove the guide plates (1) on both sides. 2 Slide the upper insert rollers (3) off the axle. Take care of the cyl.

pins. 3 Slide the first set of ejection rollers (11) off the axle. Take care

of the cyl. pins.

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Item number: 51.0067.1001.00 Page 5–67



Page 5–68

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To remove the second set of ejection rollers: 1 Remove the spring clip (5). 2 Remove the roller (4) from the axle. 3 Remove the spring clip (2). 4 Slide the axle to the left-hand side. 5 Tap out the cyl. pin of the roller (1) and slide the roller from the

axle.

GearsRefer to the figure on page 5–67. 1 Remove the guide plates (1) on both sides. 2 Remove the bracket 6 and the sensor. Take care of the wiring

of the sensor. 3 Remove the pulley (5) and the spring clip (12). 4 Slide the outer bearings at the axle (8). 5 Remove the tension springs (2). 6 Slide the axle (8) with complete insert assembly through the

slotted holes out of the frames.



Release: 07/2006

LH

RH

12

3

8

4

7

56

910

11

Refer to the figure above. 1 Remove the frame plate (5). 2 Slide the gears (4, 7 and 8) off the axles. Take care of the

pressure springs (6).

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Item number: 51.0067.1001.00 Page 5–69



Page 5–70

Refer to the figure on page 5–67. 1 Remove the screws (7). 2 Withdraw the complete ejection assembly (9) together with the

draw bar and the attached plunger (1), from the frames. Take care of the washers and the pressure spring of the plunger.

Refer to the figure on page 5–69. 1 Remove the frame plate (9). 2 Slide the gears (10 and 11) from the axles.

Ejection solenoidRefer to the figure on page 5–69. 1 Remove the covers of the loc, to get access to the solenoid. See

Section “Right-hand side cover” on page 5–5. 2 Disconnect the wiring of the solenoid. 3 Remove the two screws (3). 4 Remove the solenoid (2). Take care of the plunger (1), the

washers, and the pressure spring.




Release: 07/2006

Envelope transport and sealing

RH

LH

12

7 6 5 4 3

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Item number: 51.0067.1001.00 Page 5–71



Page 5–72

RollersSealing transport rollers 1 Open the upper unit. 2 Remove the spring clips off the axle (6). 3 Slide the transport rollers (4) off the axle. Take care of the

pressure springs (5).

Lower reverse rollersRefer to Section “Pulleys” on page 5–66.

Upper reverse rollers 1 Remove the accompanying spring clips and washers. 2 Slide the rollers (7) off the axle.

Sealing solenoid 1 Disconnect the wiring of the solenoid 1. 2 Remove the screws (2). 3 Withdraw the solenoid. Take care of the pressure spring and the

washers at the plunger.




Release: 07/2006

5.2.11 (Dis)assembly - Envelope transport

Lower ejection rollers

12

34

56

79101112

13

141516

8

17

18

19

20

21

22

LH

RH

1 Remove two screws (13) of the insert table (19) and four screws (1) of the insert table (2).

2 Remove the drive belt inserter as described in Section “Drive belt inserter” on page 5–51.

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Page 5–74

3 Remove the locking plate of the bearing at the right-hand side of the transportation axle (20).

4 Slide the axle (19) to the right-hand side. 5 Remove the cyl. pin (17). 6 Slide the roller (18) from the axle. 7 Remove the spring clip, washer and bearing from the left-hand

side of the axle (22). 8 Slide the axle to the right-hand side. 9 Slide the rollers (21) from the axle.



Release: 07/2006

Sealing track transportation rollersRefer to "Section “Pulleys”" on page 5–53 and to the figure on page 5–51. 1 Remove the pulse disc (7). 2 Remove the pulley (8) from the pulse disc axle (14).

Refer to the figure on page 5–73. 1 Remove the pressure springs (11) from the bearings (12) of the

axle (8). 2 Slide the rollers (4) aside to remove the cyl. pins (3). 3 Remove the spring clip, washer and bearing at the left-hand

side of the axle. 4 Slide the rollers off the axle.

NoteTake care of the pressure springs (10) when replacing again. On the left-hand side a spring with lower force than on the right-hand side has to be fitted.

5.2.12 (Dis)assembly - Envelope sealing and ejection

Upper sealing rollerRefer to the figure on page 5–73. 1 Remove the gear at the right-hand side of the sealing roller (6).

Refer to Section “Gears” on page 5–53. 2 Remove the pressure springs (11) from the bearings (12) and

the spring clip at the left-hand side of the sealing roller. Take care of the washer (10) and the spring (9).

3 Move the sealing roller (6) to right-hand side to free the left-hand bearing from the left-hand inside frame.

4 Withdraw the upper sealing roller.

Lower sealing rollerRefer to the figure on page 5–73. 1 Remove the upper sealing roller. Refer to the previous section. 1 Remove the gear at the right-hand side of the sealing roller (5).

Refer to Section “Gears” on page 5–53. 2 Remove the two screws (14) and the mounting plate (7). 3 Remove the spring clip, washer and bearing at the left-hand

side of the lower sealing roller (5). 4 Move the sealing roller to the right-hand side. 5 Withdraw the lower sealing roller.

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Item number: 51.0067.1001.00 Page 5–75



Page 5–76

5.2.13 (Dis)assembly - Sensors

Safety switchesUpper unit safety switch

1 2

RH

The safety switch of the upper unit is located at the right-hand side of the machine near the lowest feeder. To remove the upper unit safety switch: 1 Remove the right-hand side cover. 2 Cut the wire strap. 3 Remove the bracket (2) together with the safety switch (1). 4 Remove the safety switch from the bracket.



Release: 07/2006

Safety switch LH side cover

The safety switch is located at the left-hand side of the machine near

1 2 3

LH

the sealing rollers. To remove the safety switch (3): 1 Open the left-hand side cover. 2 Remove the cover (1). 3 Remove the safety switch (3) from the bracket (2).

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Item number: 51.0067.1001.00 Page 5–77



Page 5–78

Safety switch collator area

1 2

RH

The safety switch is located at the right-hand side beneath the colla-tor area and behind the supply cover. To remove the safety switch (2): 1 Remove the supply cover. 2 Remove the safety switch (2) from the frame (1).



Release: 07/2006

DFC and photocells

NoteWhether or not photocells are replaced, it is advised to reset the photocells after finishing servicing.

Feeders

3

2

1

LH

RH

Each feeder is equipped with a DFC. To remove the DFC: 1 Remove the covers (1, 2, 3 and 4). Refer to Section “Rubber

paper pullers” on page 5–26. 2 Remove the guide plate (5), when removing the DFC of the

feeder (2). Refer to Section “Middle feeder (feeder 2)” on page 5–21.

3 Disconnect the wiring of the DFC. 4 Remove the screw (2) securing the DFC (3) to the bracket (1).

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Item number: 51.0067.1001.00 Page 5–79



Page 5–80

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Feeder photocells

Transmitter (LED) 1 Remove the bracket (4) with the transmitter (3). 2 Disconnect the transmitter. 3 Remove the transmitter from the bracket.

Receiver (Sensor) 1 Remove the bracket (2) with the sensor (1). 2 Disconnect the sensor. 3 Remove the sensor from the bracket.



Release: 07/2006

Vertical transport

1 2 3 4

Vertical transport photocells (optical, only with OMR).In the 2,5 stations version, the detectors are located beneath the up-per vertical transport rollers.

Transmitter (LED) 1 Open the loc. 2 Remove the guide plate (1) with the assembled transmitter (2). 3 Disconnect the wiring of the transmitter. 4 Remove the transmitter.

Receiver (Sensor) 1 Remove the vertical transport cover. 2 Cut the wire strap securing the wiring of the sensor (3) to the

bracket (4). 3 Remove the bracket with the sensor. 4 Disconnect the wiring. 5 Remove the sensor.

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Item number: 51.0067.1001.00 Page 5–81



Page 5–82

Collator area

1

1 2

LH

3

1 Remove the set screw (1). 2 Remove the pulse disc. 3 Remove the sensor (3).

NoteEnsure on replacement that the pulse disc sensor clears both sides of the pulse disc.



Release: 07/2006

Collating area photocells

1

2

3

4

5

7

6

LH

RH

Transmitter (LED) 1 Move the lower collator arm downwards. 2 Remove the locking plate of the axle (4) at the right-hand side of

the machine. 3 Free the bearings of the frame. 4 Remove the hinged guide plate (1) together with the attached

sensors (2 and 3). Take care of the wiring. 5 Remove the transmitter (3) from the guide plate.

Receiver (Sensor) 1 Follow step 1 to 4 of the above procedure. 2 Remove the sensor (2) from the guide plate.

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Item number: 51.0067.1001.00 Page 5–83



Page 5–84

FolderFolder input photocell

Transmitter (LED) 1 Remove the bracket (5) with the transmitter (6) to the left-hand

side out of the left-hand inside frame. Take care of the wiring. 2 Cut the wire straps. 3 Remove the transmitter (6) from the bracket.

Receiver (Sensor) 1 Remove the bracket (5) with the transmitter (6) to the left-hand

side out of the left-hand inside frame. Take care of the wiring. 2 Cut the wire straps. 3 Remove the receiver (7) from the bracket.

Curve (pulse) disc sensor

1 2 3

LH

The sensors are located at the left-hand side of the upper unit. To re-move the sensor: 1 Open the upper unit. 2 Remove the bracket (1) with the sensor (2). 3 Cut the wire strap. 4 Disconnect the sensor. 5 Remove the sensor from the bracket.

NoteThe sensor (3) has to be removed in the same way.



Release: 07/2006

InserterPulse disc sensor

2

1

3

4

RH

The pulse disc sensor assy. is located at the right-hand side of the machine near the sealing rollers. To remove the sensor: 1 Remove the pulse disc (4). 2 Disconnect the wiring of the sensor (2). 3 Remove the two screws (3). 4 Remove the sensor.

NoteEnsure on replacement that the pulse disc sensor clears both sides of the pulse disc. To adjust the position of the sensor, slacken screw 1, reposition the sensor and fasten screw 1.

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Item number: 51.0067.1001.00 Page 5–85



Page 5–86

Envelope track photocell

LH

RH

LH

RH

1 2

34

Transmitter (LED) 1 Remove the insert table. 2 Remove the bottom plate. 3 Pull the air hose connector (4) from the transmitter (3). 4 Slacken the screw of the transmitter. 5 Remove the transmitter (3).

Receiver (Sensor) 1 Remove the insert table. 2 Remove the bottom plate. 3 Remove the bracket (2) together with the sensor (1). 4 Slacken the screw of the sensor. 5 Remove the sensor (1).



Release: 07/2006

Envelope flap detector

1 2

3

4

5

6

Transmitter (LED) 1 Remove the insert table. 2 Remove the bottom plate. 3 Remove the bracket (1) with the transmitter (2). Take care of the

wiring. 4 Disassemble the transmitter from the bracket.

Receiver (Sensor) 1 Remove the insert table. 2 Remove the bottom plate. 3 Pull the air hose connector (3) from the sensor (4). 4 Slacken the screw (6). 5 Remove the bracket (5) with the sensor (4). 6 Remove the sensor from the bracket.

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Item number: 51.0067.1001.00 Page 5–87



Page 5–88

Document insert photocells

1 2 3 4 5

LH

RH

LH

RH

Transmitter (LED) 1 Open the upper unit. 2 Remove the screw (1) to release the transmitter (2).

Receiver (Sensor) 1 Remove the transport table. 2 Slacken the screw (5). 3 Remove the bracket (4) with the sensor (3). 4 Remove the sensor from the bracket. Take care of the wiring.



Release: 07/2006

Closer photocell

321 4 6 7

RH

LH

5

To remove the flag switch: 1 Remove the nuts (1 and 6). 2 Remove the frame (2) complete. Take care of the wiring. 3 Slacken the screw (3). 4 Remove the bracket (4) with the photocell (5).

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Item number: 51.0067.1001.00 Page 5–89



Page 5–90

Exit photocells

LH

RH

1 2 3

4

1 Remove the frame axles (1) together with the cover (2). Take care of the wiring of the detectors.

2 Remove the transmitter (LED, 3). 3 Remove the receiver (Sensor, 4).



Release: 07/2006

5.2.14 Adjustment

Main drive PJ-belt

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The maximum movement of the drive belt at the indicated position is 10 mm (0.4 inch).

To adjust: 1 Slacken the two screws (1) securing the belt tensioner (2). 2 Shift the belt tensioner to adjust the correct belt movement. 3 Hold the belt tensioner in position and retighten the two screws. 4 Check the adjustment and readjust if necessary.

NoteDo not adjust the drive belt too tight.

NoteWhen adjustment of the belt tensioner is not sufficient, re-adjust the motor position.

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Item number: 51.0067.1001.00 Page 5–91



Page 5–92

Main drive belt feeders/folder

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Release: 07/2006

Main drive belt inserter

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Revision: 0

Item number: 51.0067.1001.00 Page 5–93



Page 5–94

RH drive belts

NoteThe adjustment of the lower and upper drive belt is similar.

The maximum movement of the drive belts 1 at the indicated position

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is 5 mm (0.2 inch).

To adjust: 1 Slacken the hexagonal head screw (3) securing the belt

tensioner (2). 2 Shift the belt tensioner to adjust the correct belt movement. 3 Hold the belt tensioner and retighten the hexagonal head screw. 4 Check the adjustment and readjust if necessary.




Release: 07/2006

Drive belt upper folder section

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The maximum movement of the drive belts 1 at the indicated position is 5 mm (0.2 inch).

To adjust: 1 Slacken the hexagonal head screw (1) securing the belt

tensioner (2). 2 Shift the belt tensioner to adjust the correct belt movement. 3 Hold the belt tensioner and retighten the hex. head screw. 4 Check the adjustment and readjust if necessary.


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Item number: 51.0067.1001.00 Page 5–95



Page 5–96

Paper guide

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There must be a small gap between the fixed guide plate (3) and the fold roller (2). The fold roller should just run free.

To adjust: 1 Slacken the two round head screws (1) to move the guide plate

(3) further away from the fold roller (2). 2 Tighten it to move it closer.



Release: 07/2006

Solenoids

NoteThe adjustment procedure for all solenoids is described below. Only for the finger solenoids a different procedure is necessary.

Whenever a solenoid is actuated the plunger is pulled into the sole-noid coil. To make sure that the pulling power of the solenoid coil on the plunger is maximal, the plunger should not touch the bottom of the solenoid coil whenever the solenoid is actuated.

1 2 3 4LH

RH

To set this requirement: 1 Slacken the two screws (3) securing the solenoid coil (4). 2 Push the plunger (2) together, with the linkage (1) attached to it,

as far as it will go in the direction towards the solenoid coil. 3 Hold the plunger in this position and then slide the solenoid coil

towards the plunger until the plunger bottoms the solenoid coil. 4 Move the solenoid coil back by approximately 1 mm (0.04 inch). 5 Retighten the two screws. Ensure the solenoid coil and the

plunger are aligned in a straight line.

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Item number: 51.0067.1001.00 Page 5–97



Page 5–98

Finger solenoid

1 2 3 4

RH

To adjust the finger solenoid: 1 Slacken the two screws (2) securing the solenoid coil (1). 2 Push the plunger (3) down into the lowest position. 3 Move the solenoid coil (with the plunger in the lowest position)

so that the middle fingers (slide in) is adjusted approximately 2 mm (0.07 inch) (max.) above the insert table.

4 Retighten the two screws.



Release: 07/2006

Separation rollerBecause the separation roller does not reverse, a 'flat' gradually wears on the roller surface. This can be the cause of irregular feeding of the envelopes.

Should this occur, carry out the following adjustment:

1 2

3

LH

RH

1 Use the adjusting nut (2) and set the separation gap to the maximum.

2 Slacken the set screws (1) securing the separation roller. 3 Rotate the separation roller about 30 degrees in the direction

indicated, so that the unworn portion of the separation roller faces the feed roller (3).

4 Retighten the set screw and re-adjust the separation gap.

NoteAfter rotating the separation roller over 330 degrees it is necessary to replace it.

Revision: 0

Item number: 51.0067.1001.00 Page 5–99



Page 5–100

Friction brake

� �

�

��

The friction brake is correctly adjusted when the distance between the inner faces of the two friction discs (3), i.e. the overall pressure spring length, is 20 mm (0.79 inch).

To adjust: 1 Remove the outer nut (1) securing the inner nut (2). 2 Turn the inner nut to adjust the correct distance. 3 Replace the outer nut and check the adjustment.

NoteAn increased variation of the envelope stop position can be caused by excessive play in the lower gear train. A slight reduction in the distance (increasing the pressure) may give the required result.



Release: 07/2006

Flap scraper

The flap scraper (3) must be positioned so that its lower edge is

� � � LH

RH

aligned with the lower edge of the envelope guide (1).

To adjust: 1 Slacken the two hexagonal head screws (2) securing the flap

scraper (3) on both sides. 2 Move the flap scraper to adjust the correct position. 3 Retighten the two hexagonal head screws and check the

adjustment.

NoteDepending on the envelope type and flap shape, a different setting may be necessary.

Revision: 0

Item number: 51.0067.1001.00 Page 5–101



Page 5–102

5.3 Electrical description

An overview of all PCBs:

567

1 2

3 4

Board number Board name

1 99.45.02 Display board

2 99.45.08 Keyboard

3 97.55.40 (110 V) or97.55.00 (220 V)

Motor relay board

4 99.20.03 (regular) or 99.20.01 (expanded) (optional)99.20.02 (optional)

Connection board

Modem board

5 99.20.00 (optional) Communication board

6 99.45.00 Main board

7 99.45.04 ID Tag



Release: 07/2006

5.3.1 Display board (FPi 4030 only)

Wiring display board

LC display

CCFL

LC display

touchscreen

99.4

5.4

4

LC

dis

pla

y

data

98.9

0.8

2

Connector number Cable number

J100 98.90.82

J101 LC display CCFL

J103 LC display touch-screen

J104 LC display data

J210 99.45.44

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Page 5–104

5.3.2 Keyboard

Wiring keyboard99.4

5.4

4


J100 99.45.44



Release: 07/2006

5.3.3 Motor relay board

Wiring motor relay board

main motor 99.45.26

not in

use

99.4

5.2

6

99.4

5.2

6

99.4

5.2

6

99.4

5.2

6

99.4

5.2

6

Connector number Cable number(s)

J1 99.45.26

J2 Main motor

110 V: 98.94.07

220 V: 98.94.06

J3 not in use

51 99.45.26

52 99.45.26

54 99.45.26

55 99.45.26

124 99.45.26

Revision: 0

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Page 5–106

5.3.4 Connection board

a. Connection board, regular

Wiring connection board (regular)

99.4

5.3

2


J101 99.45.32



b. Connection board, expanded (optional)

Wiring connection board (expanded)

not in use

99.45.32

99.45.32

Release: 07/2006

Modem boardThe modem board is attached to the expanded connection board.


J105 99.45.32

J108 99.45.32

Revision: 0

Item number: 51.0067.1001.00 Page 5–107



Page 5–108

5.3.5 Communication board (optional)



Wiring communication board

99.4

5.3

2

99.4

5.3

4

not in

use

99.4

5.3

2

99.4

5.4

8

not in

use

99.45.34

Release: 07/2006


J101 99.45.34

J401 99.45.32

J402 99.45.48

J403 99.45.32

J502 99.45.34

J503 not used

Revision: 0

Item number: 51.0067.1001.00 Page 5–109



Test points and LEDs on the communication board

TP105

TP207

TP207

D201

TP102

D202D203D204D205D206

TP206TP202TP208

TP106

TP201TP203

TP101

D302

Page 5–110



Release: 07/2006

Test point Name Typical value Function

TP101 GND 0 volt Debug ground

TP102 GND 0 volt Debug ground

TP105 +24V 24 volt Supply check

TP106 GND 0 volt Electrical ground

TP201 SDO Debug only

TP202 SDI Debug only

TP203 SCLK Debug only

TP205 PB 5 Debug only



TP208 PFO/CAL Debug only

LED Color Name Function

D201 Green TestLED 0 No error heartbeat

D202 Green TestLED 1 Modem activity

D203 Green TestLED 2 Inserter communication activity (USB link)

D204 Green TestLED 3 Franking interface (FIF) communication activity

D205 Green TestLED 4 Service communication activity

D206 Green TestLED 5 Debug LED

D302 Red Flsh wrt Flash write in progress indication

Revision: 0

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Page 5–112

5.3.6 Main board



Wiring main board

98.90.20

98.90.22

98.90.10

99.45.20

99.45.30

99.45.3299.45.48

99.45.34

99.45.32

98.90.32

98.90.32

98.90.32

98.94.08

98.90.30

98.90.36

98.90.34

98.90.82

99.4

5.3

6

99.4

5.2

2

99.4

5.2

4

98.9

0.3

0

99.4

5.2

6

98.9

0.2

4

98.9

0.2

8

98.9

0.1

8


Item number: 51.0067.1001.00 Page 5–113



Page 5–114


J100 98.90.30

J101 98.90.36

J102 99.45.26

J500 99.45.20

J501 98.90.20

J502 98.90.22

J600 98.90.30

J601 99.45.24

J602 99.45.22

J650 99.45.36

J700 98.90.10

J701 98.90.18

J800 98.90.28

J801 98.90.24

J802 99.45.30

J901 98.90.32

J902 98.90.32

J903 98.90.32

J1000 98.94.08 (Reading head)

J1100 99.45.32 (Without communication board)

99.45.34 (With communication board)

J1102 99.45.32 (Without communication board)

99.45.48 (With communication board)

J1120 99.45.34

J1200 (FPi 4030 only) 98.90.82



Test points and LEDs on the main board

TP503

TP501

TP600

TP502

TP1001

D300

TP205

D701

D702

D301

D301

TP800

TP906

TP500

D500

TP903

TP904

TP902

TP901

TP900

TP300

TP301

TP1000

TP200

TP204

TP202

TP101

TP100

TP700

TP701

TP201

TP203

TP105

TP103

TP505

TP102

D303


Item number: 51.0067.1001.00 Page 5–115





TP101 -12V -12 volt Supply check


TP103 GND 0 volt Electrical ground


TP200 Window 5 volt OMR window oscilloscope trigger

TP201 DBG1 X Debug only





TP300 TST1 X Debug only

TP301 TST2 X Debug only

TP500 ENV 1.2 volt Envelope photocell

TP501 FLAP 1.2 volt Flap photocell

TP502 LOC 1.2 volt Loc photocell

TP503 EXIT 1.2 volt Exit

TP505 PDSC 5 volt or 0 volt Main pulsedisc signal

TP600 CLOSER 1.2 volt Closer photocell

TP700 COLL 1.2 volt Collator photocell

TP701 FO 1.2 volt Folder photocell

TP800 PD COL 5 volt or 0 volt Collator pulsedisc

TP900 FE-1 1.2 volt Feeder 1 photocell


TP902 DFC FE1 Depends on paper thickness DFC out feeder 1

TP903 DFC FE3 Depends on paper thickness DFC out feeder 3


TP906 DFC FE2 Depends on the paper thickness DFC out feeder 2

TP1000 OMR OUT Depends on the paper reflection and marks

Analog OMR signal

Page 5–116



TP1001 ReadHead 1.2 volt Readhead photocell


Release: 07/2006

LED Color Name Function

D300 Green TST1 No error heartbeat

D500 Green PDSC Main pulsedisc indication

D701 Green FT1 Folding table 1 indication

D702 Green FT2 Folding table 2 indication

D801 Green PD COLL Collator pulsedisc indication

D301 Red TST2 Error heart beat

D303 Red Flash write Flash write in progress indication

Flex OMR (FPi 4030 only)

NoteOnly use a dongle that is marked with the number 37, DS1977 (see following figure). This dongle is not downwards compatible for other SI or SA products. Dongles marked with OC must not be used on the FPi 4030 or FPi 2000-2.

number 37

DS1977

Revision: 0

Item number: 51.0067.1001.00 Page 5–117



Page 5–118

5.3.7 ID-tag (99.45.04)

Wiring ID-Tag


J100 99.45.369

9.4

5.3

6



Release: 07/2006

5.4 Maintenance

NoteThe maintenance schedule has been published in the Technical Bulletin FP47-4030

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Page 5–120


Fault finding

6 Fault finding

Release: 07/2006

6.1 Remotely resolving problems

For remotely diagnosing customer problems, check the following with the customer:• The machine type and serial number (Look on the sticker [on the

internal frame]): 1 Open the front cover 2 Read the machine type and serial number

• The customer's failure description.• The error message coming with the failure. This can be checked

by the supervisor: 1 Enter the supervisor menu 2 Select system info 3 Read the last error 4 Check the counter since last service visit 5 Check the software versions installed

• Incase of a system with connectivity to online services, ask the supervisor to make a manual connection.

• Select a follow up process: 1 Guide the supervisor through a remote resolution process

(with or without online services). A trained remote service engineer needs to be consulted.

2 When sufficient cycles have been done since last service visit, schedule a preventive maintenance visit. Schedule enough time for both the engineer and the customer.

3 When there is no clue about the exact cause of the failure, schedule a corrective maintenance resolution process. A trained field engineer needs to be consulted.

Please noteError messages can be looked up online in the Service Knowledge Database (SKD).

Revision: 0

Item number: 51.0067.1001.00 Page 6–1


Fault finding

Page 6–2

6.2 Error handling

All error screens have the following in common:

The following machine areas/prefixes apply:

Info. Additional information if the info key 1 is pressed. → See picture below.

A message. The message that is displayed next to the exclamation mark triangle.

An action. The text that is displayed next to the finger pictogram.

An error code of the pattern X:YYY, where X is an abbre-viation that indicates a spe-cific machine part. YYY is a digit between 0 and 999, indi-cating the specific error.

Additional information, cause and remedy.

- INS = Inserter- FO = Folder- VT = Collator, vertical transport and OMR- FE1, FE2, FE3 = Feeder 1 to 3- CB = Communication board- INF = Insert‘n FrankTM


Fault finding

Release: 07/2006

6.3 Error Codes

Please noteThe following pages contain a printed version.The current Error Codes can be looked up online in the Service Knowledge Database (SKD).

Revision: 0

Item number: 51.0067.1001.00 Page 6–3

FPi 4030 / 2000-2

Error Message* Cause Information 01 02 03 04 05 06 07

Inserter errors (INS) INS:1 Technical failure FRAM chip is not available System error. This error is generated during starting

up or operation of the machine. X

INS:2 Technical failure FRAM chip is not formatted System error. This error is generated if the machine is started up (at least) the first time.

X

INS:3 Technical failure FRAM chip contains old data structure System error. This error is generated during starting up of the machine.

X

INS:4a-z Technical failure FRAM chip contains corrupt dat System error. This error is generated during reading of a data block.

X

INS:5 Technical failure Communications failure X INS:6 Technical failure Communications failure X INS:10 Envelope too long Envelope separation adjustment, envelope

type, envelope quality, envelope job settings, photocells dusty

This error is generated if a closed envelope is measured higher than 182 mm (162 mm + 20 mm tolerance) or if the envelope is measured higher than the adjusted envelope height plus 20 mm.

X

INS:11 Document inserting failure

Insert fingers, envelope stop position, envelope job settings, document skewing, document, slippage, document feeding, envelop feeding

This error is generated if the insert cell is covered too long during inserting. Too long means longer than 400 mm (800 flanks).

X X

INS:12 Document length failure

Insert fingers, envelope stop position, document job settings, document skewing, document slippage, document feeding

This error is generated if on two inserts directly after each other a length difference is measured of more than 42 mm (84 flanks). This means irregular inserting (slip on insert rollers?).

X X

INS:13 Envelope stoppage at exit

Blockage at envelope exit, inserting failure, skewing, slippage, exit blockage

This error is generated if the exit detector is covered longer than 300 ms.

X X

INS:14 Document too thin Envelope separation adjustment, envelope type, envelope job settings, photocells dusty, slippage

This error is generated if the envelope flap is not opened.

X X

INS:15 Envelope not open Envelope exit path, slippage, envelope type, inserting failure, flap closer sensor

This error is generated if the envelope does not arrive within 400 mm (800 flanks) at the exit cell, after detecting the envelope by the closer switch.

X X

State: based on rev. 01.0 - 03/2006 Page 1 of 38 Error_handling_EN_FPi4030_2000-2_20060710a.doc

FPi 4030 / 2000-2


INS:16 Envelope stoppage Envelope separation adjustment, envelope type, envelope quality, envelope job settings, photocells dusty

This error is generated if a closed envelope is measured higher than 182 mm (162 mm + 20 mm tolerance) or if the envelope is measured higher than the adjusted envelope height plus 20 mm.

X

INS:17 Unexpected document

Document path not correctly cleared after previous error, slippage, inserting failures

This error is generated if a document arrives at the insert area at a not expected moment.

X X

INS:18 Unexpected document

Document path not correctly cleared after previous error, slippage, inserting failures

This error is generated if the insert cell is covered at the moment a document is called.

X X

INS:19 Envelope stoppage Blocked envelope path, envelope separation adjustment, envelope type, envelope job settings, dusty photocells, slippage

This error is generated if the flap sensor is covered more than 690 flanks (approx. 345 mm).

X X

INS:21 Thickness not measured

Incorrect measurement area for DFC X

INS:22 Envelope too short Incorrect envelope type, envelope job settings, photocell readjustment needed

This error is generated if the envelope is measured shorter than 75 mm. Also when envelope height is measured shorter than adjusted envelope height minus 20 mm.

X X

INS:23 Envelope closer failure

Envelope path not cleared after previous jam, envelope closing sensor readjustment needed, dirty sealing track, insert failures

This error is generated if the closer cell is covered at the moment an envelope/document should leave the insert area.

X X

INS:24 Envelope closure failure

Envelope closing path not cleared after previous jam, slippage, dirty sealing track, insert failures, skewing

This error is generated if the flap closer sensor is covered too long. Longer than the time that meets a document transport of 550 flanks (approx. 275 mm).

X X

INS:26 Envelope stoppage Blocked envelope path, slippage This error is generated if the envelope or document transport from insert area to closer sensor would take too long. Longer than the time that meets 1200 flanks (approx. 600 mm).

X X

INS:27 Document stoppage Blocked document path, slippage This error is generated if the called document does not arrive at the insert cell.

X X

INS:29 Insert area blocked Blocked document or envelope path after previous stoppage

This error is generated if a document covers the insert cell at the moment the system is started.

X


FPi 4030 / 2000-2


INS:30 Empty envelope hopper

Empty hopper, wrong envelope type, envelope width setting, envelope separation adjustment, envelope feeding angle

This error is generated if it takes longer than 15 seconds to detect an envelope at the env.tracksensor after the envelope track was started.

X

INS:34 Technical failure X X INS:35 Preventive

maintenance needed Total counter equal to Service Counter, Service counter incorrect

This error is generated if the next visit service counter value is reached. The message will appear at system start.

X X

INS:36 Technical failure SCS protocol problem Check cables, connectors, PCB or software versions.

X

INS:37 Technical failure Main motor defect, pulse disc defect, cables defect

System error. This error is generated if the pulse disk of the main power does not generate enough pulses or if the broadness of the pulses is irregular. The motor is too heavily loaded or the pulse disk is defect. For the boundaries, refer to the pulse disk test in the service menu.

X

INS:38 Technical failure DFC not connected, DFC defect This error is generated if the DFC is not detected. X INS:44 Technical failure Envelope track sensor adjust error. Led

current cannot be adjusted to have photocell voltage between 0.8 and 1.3 V. Dusty, incorrect positioning, incorrectly assembled.

Photocell adjust error. This error is generated if the involved photocell can not be adjusted correctly. Transmitter power is too high and receiver power is smaller than 0.8 V (e.g. contamination, not correctly connected, not correctly aligned). Only when the system is started the first time or when the system is adjusted again after a dusty error. After a reset, the error message disappears. If the particular photocell is not needed for the selected job, the job can still be carried out. If the photocell is needed or if a new job is selected, the error appears again as soon as the start button is pressed or a test run is performed.

X

INS:45 Technical failure Envelope flap sensor adjust error Refer to INS:44 X INS:46 Technical failure Insert sensor adjust error Refer to INS:44 X INS:47 Technical failure Exit sensor adjust error Refer to INS:44 X


FPi 4030 / 2000-2


INS:48 Envelope track sensor error

Too much voltage received by photocell. Current cannot be correctly adjusted (too low)

Overexposure receiver error. This error is generated if the involved photocell is too sensitive: during adjustment the LED current becomes too low (adjustment after 25 sheets). Lower limit is 5/ 256 x100%. After pressing the reset button, the following warning message appears: 1. Remove paper at sensor position 2. Clean sensor with bellow or brush 3. Press OK to reset sensor SK4: The involved photocell values are reset. Go back to the main menu.

X

INS:49 Envelope flap sensor error

Refer to INS:48 Refer to INS:48 X

INS:50 Insert sensor error Refer to INS:48 Refer to INS:48 X INS:51 Exit sensor error Refer to INS:48 Refer to INS:48 X INS:52 Technical failure LED current adjusted too low. Envelope

track sensor adjust error Photocell adjust error. This error is generated if the involved photocell can not be adjusted correctly. The DAC current is too low (<5/256 X100%). Only when the system is started the first time or when the system is adjusted again after a dusty error. After a reset, the error message disappears. If the particular photocell is not needed for the selected job, the job can still be carried out. If the photocell is needed or if a new job is selected, the error appears again as soon as the start button is pressed or a test run is performed.

X

INS:53 Technical failure Envelope flap sensor adjust error. Refer to INS:52.

Refer to INS:52 X

INS:54 Technical failure Insert sensor adjust error. Refer to INS:52. Refer to INS:52 X INS:55 Technical failure Exit sensor adjust error. Refer to INS:52. Refer to INS:52 X


FPi 4030 / 2000-2


INS:56 Technical failure Envelope track sensor defective. Photocell, cables or connectors defect.

Power up photocell detection error. This error is generated if no LED current is detected in the involved photocell (LED incorrect or not connected) during powering up the system. After a reset, the error message disappears. If the particular photocell is not needed for the selected job, the job can still be carried out. If the photocell is needed or if a new job is selected, the error appears again as soon as the start button is pressed or a test run is performed.

X

INS:57 Technical failure Envelope flap sensor defective. Refer to INS:56.

Refer to INS:56 X

INS:58 Technical failure Insert sensor defective. Refer to INS:56. Refer to INS:56 X INS:59 Technical failure Exit sensor defective. Refer to INS:56. Refer to INS:56 X INS:60 Envelope track

sensor error Voltage received by the photocell is too high due to dust fall off

Dust error. This error is generated if the voltage in the involved photocell receiver suddenly increases significantly (e.g. by dust that falls off). Danger arises that the voltage in de receiver (> 1.5 V) stays too high when paper is present. After pressing the reset button, the following warning message appears: 1. Remove paper at sensor position 2. Clean sensor with bellow or brush 3. Press OK to reset sensor SK4: The involved photocell values are reset. Go back to the main menu.

X

INS:61 Envelope flap sensor error


INS:62 Insert sensor error Refer to INS:60 Refer to INS:60 X INS:63 Exit sensor error Refer to INS:60 Refer to INS:60 X


FPi 4030 / 2000-2


INS:64 Envelope track sensor dusty

Low voltage received by the photocell (dusty)

Dust error. This error is generated if the DAC current becomes too high during operation. You are warned if the DAC current increases and the sensor power decreases (< 0.8 V). This error is generated each 25 docs. After pressing the reset button, the following warning message appears: 1. Remove paper at sensor position 2. Clean sensor with bellow or brush 3. Press OK to reset sensor: The involved photocell values are reset. Go back to the main menu.

X

INS:65 Envelope flap sensor dusty


INS:66 Insert sensor dusty Refer to INS:64 Refer to INS:64 X INS:67 Exit sensor dusty Refer to INS:64 Refer to INS:64 X INS:68 Closer sensor error Refer to INS:48 Refer to INS:48 X INS:69 Technical failure Closer sensor adjust error. Refer to INS:52 Refer to INS:52 X INS:70 Technical failure Closer sensor defective. Refer to INS:56 Refer to INS:56 X INS:71 Closer sensor error Refer to INS:60 Refer to INS:60 X INS:72 Closer sensor dusty Refer to INS:64 Refer to INS:64 X INS:73 Technical failure Closer sensor adjust error. Refer to INS:44 Refer to INS:44 X INS:80 Technical failure SCS/I2C protocol problem, cables,

connectors, pcbs System error. This error is generated if something is wrong with the SCS/ I2C.

X

INS:81 Technical failure SCS/I2C protocol problem, cables, connectors, pcbs

System error. This error is generated if something is wrong with the SCS/ I2C.

X



X



X



X



X


FPi 4030 / 2000-2




X



X



X



X

INS:95 Sealing risk Sealing risk X INS:101 –104

Cover open Cover open, cover switches defect or loose, envelope track sensors

This error is generated if during a run a cover is opened.

X X

INS:105 Communication failure

SCS protocol problem, cables, connectors, pcbs

This error is generated if there is a SCS protocol problem.

X

INS:106 Illegal configuration Incorrect software installed This error is generated if the Inserter software does not match with the feeder/folder software.

X

INS:109 Envelope stoppage Envelope lost in envelope track This error is generated when the envelope goes under the flap opener.

X

INS:180 Update options failed ID/Option memory defect This error is generated if the addition of an option into the option memory fails, because the encrypted contents of the ID tag does not match what is expected.

X

INS:181 Option memory failure

Option memory defect or general hardware defect

This error is generated if the ID tag is not seen during power up. Reason can be that option wiring is not connected or that there is something wrong with the hardware.

X

INS:182 Option memory failure

ID memory empty, wiring defect, ID/Option memory defect

This error is generated if the ID tag could not be read, both the system ID or the options. Also when the system code is not valid (depends on the alphabet characters in the system ID). This error will occur every time the system is started, and the system can function without the options.

X


FPi 4030 / 2000-2


INS:183 Invalid data in option memory/ ID tag

The option data in the tag is not valid. It has a wrong checksum. The most likely cause of this failure is either an error in the hardware or the connection of a wrong/ uninitialized tag to a machine.

This error is generated if the entered license key (via supervisor menu) could not be recognized or translated into a valid option by the machine.

X

INS:184 Serial number already present in ID tag

Machine's software and identity are setup already

This error is generated if a machine is prepared in the factory and later on an attempt is made to prepare the machine again. Preparation (flashing and setting serial number) should only be done on pristine machines.

X

INS:185 Invalid license key entered

Invalid licence key, or licence key for other machine

This error is generated if the entered license key (via supervisor menu) could not be recognized or translated into a valid option by the system. This error can also be generated when the factory license key could not be recognized or translated to a set of valid options.

X

INS:186 Illegal configuration Illegal configuration detected This error is generated when the serial number in the ID-tag (99.45.04) does not match the serial number in the Fram of the main board. The machine is blocked from operating, because the counters in the Fram and the ID-tag (99.45.04) do not match. See Section 4.3.8 “Remove blockage”.

X

Folder errors (FO) FO:7 Document stoppage Set not removed after job change This error is generated when paper is left in the

folder after a job change. X

FO:8 Folder entry blockage

Document feeding, document separation, document path not cleared after previous stoppage, skewing of set, slippage

This error is generated if the Folder entry cell is covered longer than 500 pulses (about 475 mm). Caused by incorrect folder transport, or the document is blocking in collator.

X

FO:11 Folding failure Document set thickness, mechanical defect in first fold table, folding sensors defect

This error is generated if 500 ms after powering the clutch of the 1td fold table no flank is detected on the curve disc sensor of the first fold table. Possible causes: fold table blocking by a not foldable document (stiff material), mechanical defect on fold table, clutch or sensor.

X X


FPi 4030 / 2000-2


FO:12 Folding failure Document set thickness, mechanical defect in first fold table, folding sensors defect

This error is generated if 500 ms after powering the clutch of the 2ntd fold table no flank is detected on the curve disc sensor of the 2nd fold table. Possible causes: fold table blocking by a not foldable document (stiff material), mechanical defect on fold table, clutch or sensor.

X X

FO:14 not possible Not supported documents and envelope type detected for Fill&Start

This error is generated when due to folder limitations the fold can not be made that was calculated based on measured document lengths and envelope height.

X

FO:61 Technical failure Led current cannot be adjusted to have photocell voltage between 0.8 and 1.3 V. Dusty, incorrect positioning, incorrectly assembled


X

FO:62 Folder entry sensor error



X


FPi 4030 / 2000-2


FO:63 Technical failure LED current adjusted too low Photocell adjust error. This error is generated if the involved photocell can not be adjusted correctly. The DAC current is too low (<5/256 X100%). Only when the system is started the first time or when the system is adjusted again after a dusty error. After a reset, the error message disappears. If the particular photocell is not needed for the selected job, the job can still be carried out. If the photocell is needed or if a new job is selected, the error appears again as soon as the start button is pressed or a test run is performed.

X

FO:64 Technical failure Photocell, cables or connectors defect Power up photocell detection error. This error is generated if no LED current is detected in the involved photocell (LED incorrect or not connected) during powering up the system. After a reset, the error message disappears. If the particular photocell is not needed for the selected job, the job can still be carried out. If the photocell is needed or if a new job is selected, the error appears again as soon as the start button is pressed or a test run is performed.

X

FO:65 Folder entry sensor error

Voltage received by the photocell is too high due to dust fall off


X


FPi 4030 / 2000-2


FO:66 Folder entry sensor dusty


Dust error. This error is generated if the DAC current becomes too high during operation. You are warned if the DAC current increases and the sensor power decreases (< 0.8 V). This error is generated each 25 docs. After pressing the reset button, the following warning message appears: 1. Remove paper at sensor position 2. Clean sensor with bellow or brush 3. Press OK to reset sensor SK4: The involved photocell values are reset. Go back to the main menu.

X

Collator, vertical transport and OMR errors (VT) VT:9 Collator stop error Incorrect collator stop position, mechanical

failure This error is generated if it takes too long before a set arrives at the folder entry sensor. Is only checked at job start.

X

VT:10 Document transport failure

Document path blockage, slippage, vertical track photocells dusty

This error is generated if the document does not arrive in time at the collator entry cell (if transport time between leaving feeder and arriving at folder entry exceeds 700 mm (750 pulses).

X


Document type, document path blockage, photocells dusty, photocells defect

This error is generated if the collator entry cell is covered too long. Possible causes: too stiff material, collator blocked.

X


Document set missing from collator, photocells readjustments needed, photocells defect

This error is generated if no documents arrive at the folder entry cell. Possible causes: paper crash or the operator pressed STOP, removed the set from the collator and pressed <START>.

X X

VT:14 Unexpected document at collator

Collator not cleared after previous emergency stop

During initialisation of the collator a set (part) is seen under the folder entry cell. The collator is initialised after fatal feeder errors, after collator errors and after a change of job.

X

VT:16 Collator stop reference detection failed

Zero position sensor failure, rack broke or collator stop motor failure

During initialisation of paper stop detection the sensor for detecting zero position could not detect the zero position. Cause: zero position sensor failure, rack broke or collator stop motor failure.

X


FPi 4030 / 2000-2


VT:17 Collator stop detection failed

Stop position sensor failure, rack broke or collator stop motor failure

During initialisation of paper stop detection the sensor for detecting paper stop position could not detect the zero position. Cause: stop position sensor failure, rack broke or collator stop motor failure.

X

VT:20 Unexpected documents in system

System not cleared after job change This error is generated if documents are still in the system after a change of jobs. This can be prevented by ending a job with emptying the system, before changing jobs.

X

VT:21 Empty feeders Empty feeders, wrong document type, document width setting, manual document separation adjustment

This error is generated if all feeders are empty during the “Fill&Start” scanning session.

X

VT:61 Technical failure Led current cannot be adjusted to have photocell voltage between 0.8 and 1.3 V. Dusty, incorrect positioning, incorrectly assembled


X

VT:62 Vertical track sensor error



X


FPi 4030 / 2000-2


VT:63 Technical failure LED current adjusted too low Photocell adjust error. This error is generated if the involved photocell can not be adjusted correctly. The DAC current is too low (<5/256 X100%). Only when the system is started the first time or when the system is adjusted again after a dusty error. After a reset, the error message disappears. If the particular photocell is not needed for the selected job, the job can still be carried out. If the photocell is needed or if a new job is selected, the error appears again as soon as the start button is pressed or a test run is performed.

X

VT:64 Technical failure Photocell, cables or connectors defect Power up photocell detection error. This error is generated if no LED current is detected in the involved photocell (LED incorrect or not connected) during powering up the system. After a reset, the error message disappears. If the particular photocell is not needed for the selected job, the job can still be carried out. If the photocell is needed or if a new job is selected, the error appears again as soon as the start button is pressed or a test run is performed.

X

VT:65 Vertical track sensor error

Voltage received by the photocell is too high due to dust fall off


X


FPi 4030 / 2000-2


VT:66 Vertical track sensor dusty



X

VT:70 Technical failure Blockage of collator, collator pulse disc defect, collator motor defect

This error is generated if the DC motor of the collator is not running while it is supposed to. The error is shown when there are no pulses detected for 100 msec. This can be caused by: - a mechanical blockade as a result of which the motor is running roughly. - not properly functioning of the pulse disk of the collator. - a defect to the electric drive of the collator motor. - a defect motor.

X X

VT:71 Technical failure Refer to VT:61 Refer to VT:61 X VT:72 Collator entry sensor

error Refer to VT:62 Refer to VT:62 X

VT:73 Technical failure Refer to VT:63 Refer to VT:63 X VT:74 Technical failure Refer to VT:64 Refer to VT:64 X VT:75 Collator entry sensor

error Refer to VT:65 Refer to VT:65 X

VT:76 Collator entry sensor dusty

Refer to VT:66 Refer to VT:66 X

VT:101 Technical failure Incorrect dongle installed, dongle contents cannot be read

OMR error. This error is generated if the dongle checksum is incorrect or if the serial number check is incorrect. This error is not generated when a valid OMR dongle is removed or when an invalid dongle is placed.

X

VT:102 Technical failure Reading head dirty, LED defect, photocell defect, cables defect

OMR error. This error is generated if the LED in the reading head is defect.

X


FPi 4030 / 2000-2


VT:112 Wrong reading window position

Incorrect RD job settings OMR error. This error is generated when the reading window is behind the end of the paper.

X

VT:113 Reading stop Stop mark read OMR error. Remove the set and press <reset>. A complete set is on the collator and must be handled manually. This error is not generated in the FPi 2000-2.

X

VT:114 Suspected set Incomplete sets collected after reading error

OMR error. This error is generated after an earlier appeared reading error. The paper run commend "insert" is read. The earlier appeared reading error probably occurred halfway a set, because of which that set and the next one are incomplete.

X

VT:116 Reading stop Divert mark read OMR error. Remove the set and press <reset>. A complete set is on the collator and must be handled manually. This error is not generated in the FPi 2000-2.

X

VT:120 Reading error Less marks read than expected OMR error. This error is generated if less reading code stripes are seen, than possible with the chosen reading code. The set can - but does not need to - be taken out of the collator. After a restart, the rest of the set is finished, after which error VT:114 shows.

X

VT:121 Reading error More than 1 basic command (accumulate/ insert/ divert/ stop mark) read

OMR error. This error is generated if more paper running assignments are readable in the bar code. The set can - but does not need to - be taken out of the collator. After a restart, the rest of the set is finished, after which error VT:114 shows. This error does not show for the FPi 2000-2.

X

VT:122 Reading error No basic command (accumulate/ insert/ divert/ stop/ start/ safety mark) read

OMR error. This error is generated if no barcode line that indicates the paper run (accumulate/ insert/ divert/ stop mark) is found. Start and safety mark included. The set can - but does not need to - be taken out of the collator. After a restart, the rest of the set is finished, after which error VT:114 shows.

X


FPi 4030 / 2000-2


VT:123 Reading error Matching varies within the set OMR error. This error is generated if one sheet within a set has another match number (only with Flex code). The set can - but does not need to - be taken out of the collator. After a restart, the rest of the set is finished, after which error VT:114 shows. This error does not show for the FPi 2000-2.

X

VT:124 Reading error Sequence number of document does not match with previous document

OMR error. This error is generated if the order, as guarded by the sequence numbering of the documents, is no longer correct. The set can -but does not need to - be taken out of the collator. After a restart, the rest of the set is finished, after which error VT:114 shows. This error does not show for the FPi 2000-2.

X

VT:125 Reading error Matching number of set is not correct (related to previous set)

OMR error. This error is generated if the match number of the previous set does not join in with the match number of the current one (only with Flex code). The set can - but does not need to - be taken out of the collator. After a restart, the rest of the set is finished, after which error VT:114 shows. This error does not show for the FPi 2000-2.

X

VT:126 Reading error Parity of the marks read is not correct. Reading window incorrect? RD marks incorrect. Check RD settings.

OMR error. This error is generated if the parity of a read barcode is incorrect. The set can -but does not need to - be taken out of the collator. After a restart, the rest of the set is finished, after which error VT:114 shows.

X

VT:127 Reading error A mark is read at an illegal position OMR error. This error code is generated when a barcode line is read that can not be in that particular position (too many lines or inconsistent with other lines). The set can - but does not need to - be taken out of the collator. After a restart, the rest of the set is finished, after which error VT:114 shows.

X


FPi 4030 / 2000-2


VT:128 Reading error Incorrect marks read, RD job settings, slippage, reading head adjustments needed

OMR error. This error is generated if the position of a barcode line is moved that far, that it is arrived in the so called forbidden zone. (The forbidden zone is an area halfway two lines, that is defined as a percentage of the line distance.) The set can - but does not need to - be taken out of the collator. After a restart, the rest of the set is finished, after which error VT:114 shows.

X

VT:129 Reading error Incorrect marks read, RD job settings, reading window too long

OMR error. This error is generated if more barcode lines are present than allowed for the used barcode (only for OMR level 0). The set can - but does not need to - be taken out of the collator. After a restart, the rest of the set is finished, after which error VT:114 shows.

X

VT:134 Too many documents

Set size exceeds maximum number from RD job settings, incorrect marks read

OMR error. Remove the set and press <RESET>. To subsequently restart the system, press <START>. During collating through reading, a set should always be completed. However, a maximum set size is indicated in the OMR setting menu (attachments are included). When this maximum size is reached, the collating stops and this error is generated. This does not happen during overlapping supply from the feeders.

X

VT:135 Final set part Incorrect marks read, RD job settings OMR error. This error is generated if the remains of the set (until the insert sign) are collated after removing an incomplete set and pressing <RESET> and <START> for error VT:134. If, subsequently, again the maximum amount of sheets in a set is exceeded, error VT:134 is generated again.

X

VT:137 Reading error No safety mark read OMR error. This error is generated when a safety mark is not read. The set may be removed from the collator. Pressing <RESET> and <START> will result in error VT:134 Suspected set.

X


FPi 4030 / 2000-2


VT:138 Reading error Group start mark error OMR error. This error is generated when a group start mark is not read. The set may be removed from the collator. Pressing <RESET> and <START> will result in error VT:134 Suspected set.

X

VT:139 Reading error Group end mark error OMR error. This error is generated when a group end mark is not read. The set may be removed from the collator. Pressing <RESET> and <START> will result in error VT:134 Suspected set.

X

Feeder errors (FE) FE1:0 Empty feeder Empty feeders, wrong document type,

document width setting, manual document separation adjustment

This error is generated if a feeder is empty. This can be put right by refilling the feeder and pressing <RESET>. This is no fatal error; after restarting the job, the set will be finished. In order to do a restart after this error, press the start button.

X

FE1:10 Document too thick Document type, document separation adjustment (manual separation only), separation rollers worn out

This error is generated if a feeder inserts a double page. This is a fatal error.

X

FE1:11 Feeding failure Incorrect thickness reference, irregular document types, DFC defect or loose

This error is generated if the sheet on which the DFC is adjusted was a double sheet. This error can only be generated with the first sheet that a feeder hands in after adjustment (when this sheet is thinner than the one that was used for the adjustment). This is a fatal error.

X X

FE1:12 Document too long Document separation adjustment (manual separation only, document type, document job settings, photocells dusty

This error is generated if a feeder hands in a document that is more than 20% longer than the document size that was set up for that feeder in that particular job. This is a fatal error.

X X

FE1:13 Document stoppage Blocked document path, document separation adjustment (manual separation only), document type, document job settings, photocells dusty

This error is generated if a feeder is handing in a document and it is found that the document is at least 50% longer than the document size that was set up for that feeder in that particular job. This is a fatal error.

X X

FE1:14 Document too short Incorrect document type, document job settings, photocell readjustment needed

This error is generated if a feeder hands in a document with a length that is more than 45 mm shorter than the document size that was set up for that feeder in that particular job. This is a fatal error.

X X


FPi 4030 / 2000-2


FE1:20 MaxiFeederTM failure Incorrect job settings for MaxiFeederTM This error is generated if an MF is plugged in and a job is started that does not comply with the specifications of the MF-3. This can occur when the lowest feeder is a complete station, and the doc length is adjusted to >156 mm and/or to multifeed.

X

FE1:21 Unauthorized job Incorrect document job settings, dongle reading failure

This error is generated if a 2 station machine is reconstructed to a 1.5 station machine (dongle removed) and a job is started that does not comply with the specifications for a half station. This is the case when the doc length for that half station is adjusted to >156 mm and/or to multifeed.

X

FE1:22 MaxiFeederTM failure Refer to FE1:20 Refer to FE1:20 X FE1:51 Technical failure Led current cannot be adjusted to have

photocell voltage between 0.8 and 1.3 V. Dusty, incorrect positioning, incorrectly assembled


X

FE1:52 Feeder sensor error Too much voltage received by photocell. Current cannot be correctly adjusted (too low)


X


FPi 4030 / 2000-2


FE1:53 Technical failure LED current adjusted too low Photocell adjust error. This error is generated if the involved photocell can not be adjusted correctly. The DAC current is too low (<5/256 X100%). Only when the system is started the first time or when the system is adjusted again after a dusty error. After a reset, the error message disappears. If the particular photocell is not needed for the selected job, the job can still be carried out. If the photocell is needed or if a new job is selected, the error appears again as soon as the start button is pressed or a test run is performed.

X

FE1:54 Technical failure Photocell, cables or connectors defect Power up photocell detection error. This error is generated if no LED current is detected in the involved photocell (LED incorrect or not connected) during powering up the system. After a reset, the error message disappears. If the particular photocell is not needed for the selected job, the job can still be carried out. If the photocell is needed or if a new job is selected, the error appears again as soon as the start button is pressed or a test run is performed.

X

FE1:55 Feeder sensor error Voltage received by the photocell is too high due to dust fall off


X


FPi 4030 / 2000-2


FE1:56 Feeder sensor dusty Low voltage received by the photocell (dusty)


X

FE1:60 Feeding failure Document separation failing, DFC defect, Cables defect

This error is generated when the DFC can not see the difference between paper being present or not present. This can be caused by a continuous flow of paper (no space in between sheets) or by a defect in the DFC. After reset, a new reference value is taken. When still no difference is measured, error FE1 t/m FE3):61 shows. There is a defect in the DFC.

X X

FE1:61 DFC failure DFC defect, cables defect This error is generated if the DFC can not be adjusted.

X

FE1:62 Technical failure DFC defect, cables defect This error is generated in a job where the DFC is turned on while it is defect. This error returns after each change of job.

X

FE2:0 Empty feeder Empty feeders, wrong document type, document width setting, manual document separation adjustment


X



X X


FPi 4030 / 2000-2




X X



X X



X X



X


X



X

FE2:22 MaxiFeederTM failure Refer to FE1:20 Refer to FE1:22 X


FPi 4030 / 2000-2




X


X


X


FPi 4030 / 2000-2




X



X

FE2:60 Feeding failure Document separation failing, DFC defect, Cables defect


X X


X


X


FPi 4030 / 2000-2


FE3:0 Empty feeder Empty feeders, wrong document type, document width setting, manual document separation adjustment


X



X X



X X



X X



X X



X


X


FPi 4030 / 2000-2




X

FE3:22 MaxiFeederTM failure Refer to FE1:20 Refer to FE1:22 X FE3:51 Technical failure Led current cannot be adjusted to have

photocell voltage between 0.8 and 1.3 V. Dusty, incorrect positioning, incorrectly assembled


X



X


FPi 4030 / 2000-2



X


X



X


FPi 4030 / 2000-2




X X

FE3:60 Feeding failure Document separation failing, DFC defect, cables defect


X


X


X

Communication board errors (CB) CB:0 New online service

messages New OLS message on communication board

OLS message. At start up of system when OLS is enabled and new messages are available in OLS menu.

CB:1 Technical failure System serial number memorized in communication board is not the same as on ID tag. Most likely because of exchanged connection board from an existing system.

OLS or INF error. At IN startup and configuration check. Communication board is configured on a different inserter than the current inserter (based on serial number). After reset error: choice "Continue without action"or "Initialise communication board".


FPi 4030 / 2000-2


CB:2 Technical failure Communication board missing or defect, or internal cables or PCB defect

OLS or INF error. At IN startup and configuration check. Also when INF info is needed (INF job start, INF job adjust). Communication board is expected because of service settings or licence. Cause: internal Cables, PCB defect.

CB:4 Technical failure No modem available/ detected, modem defect, modem not plugged in, cable defect, no connector board, connector board defect

OLS error. At IN startup and configuration check and modem is expected because of service settings or licence.

CB:5 Technical failure The installed modem could not be detected as a legal version

OLS error. At IN startup and configuration check and modem is expected because of service settings or licence.

CB:6 Technical failure Internal cables defect or Communication/ Connection board defect

INF error. At IN startup and configuration check (only when INF options are enabled). Also when INF job is started or INF job is edited and no communication is possible.

CB:7 Technical failure Modem not ready or serial port initialisation of modem failed

OLS error. At IN startup and configuration check (only when OLS is switched on in service menu).

CB:8 Technical failure Clock update received from server failed During run, system should continue. CB:9 Technical failure Communication board has had power dip OLS error. At IN startup and configuration check

(only if OLS is switched on in service menu).

CB:10 Auto connection failure

Automatic connection failed. Statistic buffer overflow >95%, batch data might be lost

OLS error. During operations, when stop or clear is pressed and the system is stopped, and allocated memory is getting full. Only when OLS is on en options statistics is enabled.

CB:11 Technical failure FRAM chip not available on communication board

During start up, and OLS/FIF is enabled.

CB:12 Technical failure FRAM not formatted During start up, and OLS/FIF is enabled. CB:13 Technical failure FRAM contains old data structure During start up, and OLS/FIF is enabled. CB:14a.. z

Technical failure FRAM contains corrupt data When reading data block.

CB:15 Technical failure Incorrect software in communication board or inserter board

At IN startup and configuration check. Communication board is expected because of service settings or licence.


FPi 4030 / 2000-2


CB:16 Technical failure PCB communication board failure During start up of the system (and OLS/FIF is enabled).

CB:17 Technical failure ISIS link down between main board and communication board

Communication lost between inserter and communication board.

CB:50 No analogue phone detected

There is no analogue phone line connected to the machine or the line is faulty

OLS message: At Osiris connection set up Check the phone-line.

CB:51 No dial tone The modem failed to detect a dial signal. Could also happen if the phone-line is not connected

OLS message: At Osiris connection set up Check the phone-line (e.g. by connecting a normal analogue phone and listening to the receiver. If there is a Dalton, try disabling the dial tone detect in the OLS configuration screen on the device).

CB:52 OLS dialling interrupted by user

The user/supervisor pressed the disconnect button while dialing out

OLS message: At the initiation of a new OLS connection and the drilling is interrupted by user.

CB:54 OLS line busy The phone number being dialed is busy OLS message: At the initiation of a new OLS connection and there is no incoming phone line available at the server or there is congestion on the public phone network. Try again later.

CB:57 OLS connection refused by server

At setting up an OLS connection the authentication process of the system failed because system is not allowed to connect

OLS message: The IP settings are not correct. Check IP number and port. Also it could be that the device is not allowed to authenticating.

CB:58 Protocol error The connection to the server succeeded but the server doesn't allow this device to communicate with the server

OLS message: The device is not know by the server. Check on the OLS server if this device serial number is known by the server.

CB:61 Automatic stats upload failed

The upload of statistics is interrupted Ask OLS server administrator to investigate.

CB:62 Configuration upload/download failed

The upload of the configuration information is interrupted

Ask OLS server administrator to investigate.

CB:63 Automatic software download failed

A software download is interrupted Ask OLS server administrator to investigate.

CB:64 Automatic job download failed

A job download is interrupted Ask OLS server administrator to investigate.

CB:65 Automatic feature download failed

A feature download is interrupted Ask OLS server administrator to investigate.


FPi 4030 / 2000-2


CB:66 Automatic flex code download failed

A flex OMR download is interrupted Ask OLS server administrator to investigate.

CB:67 No carrier The modem failed to negotiate with the modem of the server

OLS message: At the initiation of a new OLS connection. This could have multiple reasons. E.g. the quality of the line is bad or the negotiation with the modem of the server failed. Try again later. If it continues to fail repeatedly verify line signal quality for example by connecting an analogue phone to the line and listen to the dial tone, try to make an external call.

Insert‘n FrankTM errors (INF) INF:00 Cover open on

franking machine Cover opened during INF run

INF:1 Franking machine stopped via start/stop key

This error is raised when the user pressed the 'Stop' button on the FM during a run resulting in an emergency stop. The last envelopes(s) that left the franking machine might not be franked.

INF:2 No communication with franking machine

Due to a time out INF decided that communication with the FM has dropped. Caused by an internal problem at the FM or by disconnecting the serial cable. Check the cabling and restart the job from the IN. If this fails, switch off/on the FM or the whole system.

At changing DS+MS job settings (for which information from FM is needed), job info or starting DS+MS job. In job edit, after reset: continue the job edit menu. The fields that can not be adjusted and knobs that belong with that fields are grey. Only "pass through" can be selected.

INF:3 Envelope stoppage between inserter and franking machine

This error is raised when an envelope is not franked within X seconds after having left the insert area (system and configuration dependent). The envelope might not be franked by the FM.

During run.

INF:4 More envelopes have been franked than sent by the inserter system

Possible presence of envelopes in FM from previous job, or envelopes manually put onto the FM during the job, so more envelopes have been franked than was foreseen by the INF.

During run.


FPi 4030 / 2000-2


INF:5 Internal error on franking machine

At the FM an error has occurred that permanently blocks execution of the current run. The user has to look at the UI of the FM for more details. Best case, the job can be started again after resolving the problem. Worst case the FM has to be switched off/on.

During run or pressing start key.

INF:6 Error or warning on franking machine

At the FM an error has occurred that temporarily blocks execution of the current run. The user has to look at the UI of the FM for more details. After solving the problem, the run will be resumed automatically.


INF:7 Communication failure with franking machine

Due to some unsupported error (condition) the FM refuses to start. The user has to try to start the job from the IN again. If this fails the FM has to be switched on/ off.

When pressing start key.


INF received incorrect envelope data (unknown hopper or invalid hopper data). Remove any envelopes from the system and try to start the job again.



INF received incorrect envelope data (unknown thickness or invalid thickness data). Remove any envelopes from the system and try to start the job again.


INF:10 Selecting franking machine job failed

Unable to select a job at the FM due to an unsupported error (condition). Try to restart the job again or switch off/on the FM.


INF:11 An internal error occurred which blocks job execution

Unable to make some settings at the FM due to an unsupported error (condition). Try to restart the job again or switch off/on the FM.

During run.


FPi 4030 / 2000-2



Unable to retrieve settings from the FM due to an unsupported error (condition). Try to restart the job again or switch off/on the FM.

During run.


Unable to configure the 'Base' (FM) due to an unsupported error (condition). Try to restart the job again or switch off/on the FM.



Unable to configure the 'Advanced Feeder' (AF) due to an unsupported error (condition). Try to restart the job again or switch off/on the FM.



Due to some unsupported error (condition) INF is unable to stop the FM. Switch off/on the FM.


INF:16 Franking machine is in stand alone mode

The FM is being used 'stand alone'. As a result INF cannot gain control over the FM.

At changing DS+MS job settings (for which information from FM is needed), job info or starting DS+MS job. In job edit, after reset: continue the job edit menu. The fields that can not be adjusted and knobs that belong with that fields are grey. Only "pass through" can be selected.


Due to some unsupported error (condition) the FM did not complete the starting sequence in time. Try to start the job again or switch off/on the FM.

During run.


A time-out occurred when attempting to wake up the FM from sleep/stand-by mode. The FM did not wake up in time. Try to start the job again or switch off/ on the FM.

During run.

INF:19 Franking machine already started

The FM cannot be started as it is already running. Probably the user started the FM manually or the FM was not stopped in the previous job. If not, switch off/on the FM.



FPi 4030 / 2000-2


INF:20 Internal error on franking machine

The FM decided to execute an emergency stop. However, it did not provide any further information for the reason. Try to start the job again or switch off/ on the FM.


INF:21 Selecting franking machine job failed

Inserter job is coupled to a non-existing FM job (the specified job ID is empty). Update the job definition at the IN or create a job at the FM.

At changing DS+MS job settings (for which information from FM is needed) or starting DS+MS job. In job edit, after reset: continue the job edit menu. The fields that can not be adjusted and knobs that belong with that fields are grey. Only "pass through" can be selected.


Indicates that the FM won't accept commands and/or data from INF. Just wait and try to start the job again or switch off/on the FM.


INF:23 The franking machine is in error mode

INF is not able to configure the FM as some error has occurred that has not yet been solved and is not specified. Please check the FM UI for any message and close any covers. Otherwise switch off/on the FM.


INF:24 The franking machine is in busy mode

INF is not able to configure the FM as the FM is busy for some unknown. reason Please wait a while, otherwise switch off/on the FM.


INF:25 Internal failure on franking machine

Unable to configure the 'Dynamic Scale' (DS) due to an unsupported error (condition). Try to restart the job again or switch off/on the FM.



The FM did not complete the stop sequence in time. The FM might have to be switched off/ on in order to continue with another job.



During job execution the FM terminated the job unexpectedly for some unknown reason. Try to restart the job again or switch off/on the FM.



FPi 4030 / 2000-2


INF:28 Auto clean on franking machine in progress

Notification from the FM that the Auto Clean Cycle will be started very soon.


INF:29 Cover open on franking machine

Franking machine cover open, cover switches defect or loose? Close the cover. This error is only generated when the cover switch is activated. It does not register if the cover is open or closed.



Due to some fatal error condition communication with the FM has dropped in Alayer. Try to start the job again or switch off/ on the FM or the system as a whole.



Due to some fatal error condition communication with the FM has dropped in Tlayer. Try to start the job again or switch off/ on the FM or the system as a whole.



Due to some fatal error condition communication with the FM has dropped in Dlayer. Try to start the job again or switch off/ on the FM or the system as a whole.


INF:33 Communication failure

INF received an envelope from the IN but the data for that envelope was either lost or never delivered to INF. INF is unable to recover from this situation. Remove the envelope from the waiting position and start the job again.


INF:34 Wait position occupied

INF received data for the next envelope while the current envelope has not yet left the waiting position. Restart the job.


INF:35 User PIN code required at franking machine

The FM has popped up a dialog to enter the user PIN code. Job execution will be blocked until the correct PIN code has been entered.



FPi 4030 / 2000-2


INF:36 Department PIN code required at franking machine

The FM job selected requires a department PIN code. INF does not support this feature. Job execution is blocked. Either the PIN code has to be removed or another FM job has to be selected.


INF:37 Wrong PIN code entered on franking machine

The user has entered the wrong PIN code and the FM will go into 'sleep' mode. Job execution is blocked.


INF:38 Unknown envelope detected

INF has detected a physical envelop at the wait position, but did not receive any data for it. The envelope (if any) has to be removed.


INF:39 Unknown envelope detected

INF has detected a physical envelop at the wait position, but was not notified about its arrival. The envelope (if any) has to be removed.


INF:40 Auto clean on franking machine is finished

Notification from INF that the Auto Clean Cycle has been completed and the franking process will be resumed automatically.


INF:41 Auto clean on franking machine time out

Notification from INF that the Auto Clean Cycle takes more time than expected. Either the user wait until the FM has actually finished Auto Clean or the FM has to be switched off/ on.



For some reason the FM is busy and won't accept commands from INF. Possibly the FM was manually started by the user. Otherwise the FM has to be switched off/ on.


INF:43 The franking machine is in supervisor mode

An attempt is made to execute a job while the FM is in Supervisor mode. Exit Supervisor mode at the FM and try to start the job again.



FPi 4030 / 2000-2


INF:44 Franking machine not ready for franking interface

At the FM is currently a dialog being displayed as a result of an error (condition) that occurred while INF was not executing a job on the FM. Probably the FM was used stand alone. Inspect the FM UI and act upon it.



Concerns incorrect set up of the option. The INF level is set to INF_LEVEL_NO_INF. Probably caused by incompatible software versions of Inserter and INF module. Internal error, not user solvable.



Concerns incorrect set up of the option. An attempt was made to set the franking mode to an invalid or no longer supported mode. As a result the current franking mode is retained. Probably caused by incompatible software versions of Inserter and INF module.



INF is busy and cannot accept any commands. An attempt was made to change settings while INF is busy. Internal error, not user solvable. Just try again later and ultimately switch off/on the whole system.


INF:48 ZIP zone required at franking machine

The FM has popped up a dialog to enter the ZIP Zone. Job execution will be blocked until a ZIP Zone has been entered.


INF:49 Franking machine job selected includes Dynamic batch mode

An attempt is made to start an FM job from the IN. The FM job includes "Dynamic Batch Mode" which is not supported when KEOPS is in "Inserter Mode". This job is blocked by INF - either the user has to switch off "Dynamic Batch Mode" or has to select another job.



FPi 4030 / 2000-2


INF:50 Sealing on advanced feeder of franking machine is selected

An attempt is made to start an FM job with sealing on AF selected. The user can only solve this by modifying the FM job (disable sealing) or modifying the IN job.


INF:51 Sealing on advanced feeder of franking machine is selected

An attempt is made to start an FM job with sealing on the MMF/AF selected. This can be overruled through the service menu setting.

It is recommended to seal through the inserter. This warning is generated when pressing the start key.

INF:52 Manual clean of cartridge on franking machine failed

An attempt to force to clean the cartridge manually failed. Not user solvable! Just try again and pray…


INF:53 The franking value exceeded the 'High value threshold'

A job was started in which the franking value exceeded the 'High value' threshold. The user has to confirm this high value at the FM by either pressing 'OK' or 'ESCAPE'. The user has to confirm this high value at the FM by either pressing 'OK' or 'ESCAPE'.


INF:54 Franking machine stopped via escape key

The user has aborted the franking cycle by pressing 'ESCAPE' at the FM. The job will be aborted.


INF:55 FIFO Overflow FIFO Overflow for PPC variable mode When pressing start key. INF:56 Weight exceeds limit Check weight values in job settings When pressing start key. INF:57 Rate calculation Rate calculation failure When pressing start key. INF:58 Envelope measures Invalid envelope measure for PPC

management When pressing start key.

INF:59 No active rate table No active rate table - probably Base only, activate rate table.




Fault finding

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Upgrading and installing accessories

7 Upgrading and installing accessories

Release: 07/2006

7.1 Conveyer stacker (FPi 4030 only)

See separate document: Mounting instructions Conveyer stacker.

7.2 OMR

See separate document: Mounting instructions OMR.

7.3 MaxiFeederTM (FPi 4030 only)

See separate document: Mounting instructions MaxiFeederTM MF2.

7.4 Online services

See separate document: Mounting instructions Connectivity kit and Getting connected.

7.5 Insert‘n FrankTM (not yet available)

See separate document: Mounting instructions Franking/Mailing in-terfaces.

7.6 Intermediate transport

See separate document: Mounting instructions intermediate trans-port.

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Upgrading and installing accessories

Page 7–2


Technical Specifications

8 Technical Specifications

Release: 07/2006

8.1 Technical specifications

8.1.1 Machine specifications

Model: FPi 4030

Type: Inserter system for medium office use

Noise level: < 70 dB(A) (following ISO 11203)

Power consumption: 100V AC / 50 Hz / 5.0 Amps

115V AC / 60 Hz / 5.0 Amps

230V AC / 50 Hz / 2.5 Amps

Processor: 32 bits ARM7

Memory: 16 Mb SDRAM and 4 Mb flash ROM

Approvals: EMC Certificate conform EMC-Directive

FCC Certificate conform 47CFR, part 15

CB Certificate conform IEC 60950

UL Listed I.T.E. (Information Technology Equipment), conform

UL-IEC 60950, file E153801

Conform NEN-EN-IEC 60950 and derivates

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There are 2 models:• FPi 4030: 3 standard feeders• FPi 4030 Special: 2 standard feeders and 1 special feeder at the

bottom

The 2 types of feeders are:• Standard feeder: typically for normal address carrier documents

from laser printers, impact printers, copiers and also some glossy papers depending on a test.

• Special feeder: not only for special papers such as glossy papers, small booklets pre-folded inserts, but also for normal paper.

Features FPi 4030 FPi 4030 Special

Number of Feeders: 3 3

Glossy papers, pre-folded, booklets processing: Some, test depend-ent

Yes

Daily mail: Yes Yes

Automatic fold settings: Yes Yes

Full programmable jobs: Yes Yes

Feeder swap*: Yes Yes

Multi sheet feeder: Yes Yes

Secure’n FeedTM on all feeders: Yes Yes

Fill & Start®: Yes Yes

BRE MaxiFeederTM Option Option

OMR Levels 1, 2, 3 and Flex: Option Option

Conveyor stacker: Option Option

Side exit: Option Option

Insert‘n FrankTM Level 1, 2 and 3 **: Option Option

Adjustable height furniture: Option Option

* Not possible in combination with OMR** availability country/organisation dependent



Release: 07/2006

8.1.2 Documents

Paper height: minimum 90 mm (115 mm for FE-3, unless intermediate transport option is used)

maximum 356 mm (14")

Paper width: minimum 130 mm

minimum maxi feeder 140 mm

maximum (no fold, no insert) 242 mm

maximum (no fold) 236 mm

maximum with fold 230 mm

Paper weight: minimum 60 gr/m2

maximum without folding: 250 gr/m2

maximum with fold 170 gr/m2

Brochures: maximum thickness (no fold) 1 mm

If flexible and back/fold leading into feeder

Reply envelopes: minimum weight 80 gr/m2

minimum size 90x130 mm (height x width), with MF-1/2: 90x140

maximum size 156x236 mm (height x width)

Set thickness: Max. number of sheets to be folded:

8 x 80 gr/m2 (single fold)

6 x 80 gr/m2 (letter fold, Z-fold)

3 x 80 gr/m2 (double parallel fold)

Max. set thickness to be conveyed through folder: 2.5 mm

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Max. number short, documents not to be folded is 25 sheet of 80 gr/m2. Depending on paper quality this is limited to 12-25 sheets of 80 gr/m2.

Max. thickness of a set after folding is: 2.5 mm

Note:

When sets are at maximum thickness (e.g. 5-6 sheets letter fold), it might be necessary to tune the fold settings for good inserting and exit (especially side exit). For example, for A4: fold not 108/216 but 105/210.

Set height: max.set height 156 mm (or envelope height +/- 6 mm)

max set height (with not inserting) 203 mm, and mutual difference address fold and set height/residual length max. 50 mm.

min. set height 84 mm

min. set height (with not inserting) 102 mm

Kinds of paper: Normal standard feeder

MC shiny up to and including mat standard feeder

Recycled paper standard feeder

Booklets standard feeder

Prefolded paper: A3 double to A4 special feeder

A4 folded to A5 or 4" or booklets special feeder

Reply Envelopes special feeder

Notes:

Powdered paper, NCR, satinated paper will not be able to achieve the reliability of the standard feeder.

Prefolded and reply envelopes can possibly be processed by the standard feeder. This should be tested with each customer application.

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Release: 07/2006

8.1.3 Envelopes

Height: minimum 90 mm

maximum 162 mm

maximum at presentation with open flap:

Envelope + flap max. 165 mm

Width: minimum 160 mm

minimum Set width +12 mm with single sheet, increasing to +28 mm for 8 sheet multi-ple fold

maximum 248 mm

Flap height: minimum 32 mm (in middle)

maximum envelope height minus 32 mm

Décolleté: min. 10 mm, on 43 mm from the mid-dle. Outside this may be lower

maximum 75 mm

Paper grade: minimum paper weight: 45 gr/m2

maximum paper weight: 120 gr/m2

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8.1.3.1 Insert specifications

A B C D E F G

Minimum size mm 160 90 32 10 130 84 60 g/m2

inches 6.3 3.5 1.25 0.4 5.1 3.3 60 g/m2

Maximum size*

mm 248 162 B-32 35 A-12** B-6 2.5***

inches 9.7 6.38 B-1.25 1.4 A-0.47** B-0.2 0.1

* Maximum insert specifications are based on single sheets. When multiples are handled, more room inside the envelope is needed depending on the application.

** When insert is more than 1 mm (0.04 inch): A-15 mm / A-0.6 inch

*** Booklets up to approximately 1 mm (0.04 inch) thickness, depending on stiffness

Notes• The specification of the paper handling equipment is often wider

than that of the envelopes and documents handled. The condi-tion of material handled will limit the specified environmental con-ditions.

• We recommend that materials to be handled are stored at a tem-perature of 20°C (68°F) with a relative humidity factor of 50%. If difference in temperature occurs between store room and mailing area, the material has to be stored near the machine at least 24 hours before use.

• Self-copying paper may cause rubber parts to wear quicker. The rubber used in this machine has the best resistance to Wiggins Teape material.



Release: 07/2006

8.1.4 Capacity feeders and exit options

Capacity feeder hopper: 325 sheet 80 grm/m2, this is approximately 3.7 cm

Capacity BRE MaxiFeederTM: 325 reply envelopes

Capacity envelope hopper: 160-170 mm (325 empty envelopes 80 gr/m2)

Capacity envelope exit options:

Catch tray 100 env C5/6 with 1xA4 80 gr/m2 multiple fold

Stacker 150 env C5/6 with 1xA4 80 gr/m2 multiple fold

Stacker+extension 300 env C5/6 with 1xA4 80 gr/m2 multiple fold

Side exit 225 env C5/6 with 1xA4 80 gr/m2 multiple fold

8.1.5 Fold types

The FPi 4030 has two folding tables, both in upwards position seen from the paper path. The following folds are possible:• No Fold• Single fold • Letter fold• Double parallel• Z fold

Feeding instructions:

Address/ Fold type Z-fold Other folds

Address carrier loaded in Bottom station or Top station¹ Top station

Address face ... Down Up

Address position Trailing Leading

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Folding table limitations:

Maximum depth 1st folding table 255 mm

Maximum depth 2nd folding table 150 mm

Minimum depth in 1st and 2nd folding table 25 mm

Minimum distance back of document to fold 75 mm

2nd folding table, with multiple fold:

distance between both folds minus residual length =< 105 mm

8.1.6 Processing speed

There are 3 fixed stop positions on the collator.These positions are:• a: A5• b: A4• c: 14"



Release: 07/2006

The actual stop position used depends on the set length of the cur-rent job, and will be automatically activated:

• When the set length is 148 or shorter stop, "a" will be used.• When the set length is 149 to 297 stop, "b" will be used.• When the set length is 298 to 356 stop, "c" will be used.

System speed per job:

Feeder 3: 1xA4 3xA4 2xA4

Feeder 2: 1xA4 1xA4 1xA4 2xA4

Feeder 1: 1xA5 1x11" 1xA4 1x14" 1x100 1xA4 1xA4 1x100 1x100

Fold: E 108 W 99/198

W 108/216

DP 99/198

W 96/204

W 108/216

W 108/216

W 106/212

W 106/212

Collator at: a b b c b b b b b

Mode: 2 2 2 2 2 2 2 2 2

Doc offset: 50 50 50 50 50 50 50 50 50

BRE offset: yes yes yes yes yes yes yes yes yes

Envelope: C5/6 (114)

#10 (105)

C5/6 (114)

#10 (105)

C5/6 (114)

C5/6 (114)

C5/6 (114)

C5/6 (114)

C5/6 (114)

Output/hour:

3500 3060 3000 2500 2650 2650 2200 900 900

8.1.7 Configuration dimensions

Length: 765 mm on covers

1120 mm including hopper (90 mm) and collator /doc.hoppers (265 mm)

1260 - 1360 mm including standard Exit (catch tray)

1200 mm including side exit

Width: 460 mm (the optional side exit is 90-195 mm outside side cover)

Height: 680 mm

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Page 8–10

8.1.8 System operation control

Features Performance

Number of jobs programmable 20

Fold settings Central

Screen size 20mm * 90 mm

Screen resolution Resolution: 320 * 240 pixels

Screen technology Full color touch screen

8.1.9 Other general specifications

Features Performance

Noise level <70 sBA (68 dBa)

Operating temperature 10° C - 40° C

Operating humidity 30% - 80%

Power requirements 230V/50Hz (voltage tolerance: +10%/-10%)115V/60Hz (voltage tolerance: +6%/-10%)100V/50Hz (voltage tolerance: +6%/-10%)

Weight Whole system: 73 kg

8.1.10 Quality

Maximum volume per month: 40,000 envelopes

8.1.11 Operating modes

Daily mail(manual feeding)

Automatic feeding

Fold only Yes Yes

Insert only Yes Yes

Fold + Insert Yes Yes



Release: 07/2006

8.1.12 Optical Mark Recognition

8.1.12.1 Concept

• One track OMR code only• Factory fitted as well as Field upgradeable• Available levels: Level 0, 1, 2, 3 and Flex

8.1.12.2 Reading marks and their meaning by level

Reading code parameter

Value Description Level FP-Level

Start mark Yes Start mark 1*, 2*, 3 B

Start mark No No start mark 1*, 2*, 3 B

Insert on Mark Mark is insert; space is accumulate 0 ,1*, 2*, 3 0**,B

Insert on Space Mark is accumulate; space is insert 0,1*, 2*, 3 0**, B

Divert & Continue Yes Divert mark (not supported) 3 B

Divert & Continue No No divert mark (not supported) 3 B

Stop mark Yes Stop mark 2*, 3 B

Stop mark No No stop mark 2*, 3 B

Selective feed 1 Yes Selective feed on station 1 2*, 3 B

Selective feed 1 No No selective feed on station 1 2*, 3 B

Selective feed 2 Yes Selective feed on station 2 2*, 3 B

Selective feed 2 No No selective feed on station 2 2*, 3 B

Sequence check No No sequence check 3 B

Sequence check 3 Yes Sequence check with 3 marks 3 B

Sequence check 2 Yes Sequence check with 2 marks 3 B

Sequence check 1 Yes Sequence check with 1 mark 3 B

Parity check Yes Parity check, based on a parity mark (even)

1*, 2*, 3 B

Parity check No No parity check 1*, 2*, 3 B

Safety mark Yes Safety mark 1*, 2*, 3 B

Safety mark No No safety mark 1*, 2*, 3 B

Line spacing 4-10 lpi Line spacing in increments/ decrements of 1/32” Displayed in 2 digits in lpi and mm

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Notes 1 When some functions are not used, marks will shift up. 2 The divert and continue mark cannot be used. The divert and

stop mark will make the set stop before folding in the collating area.

3 Selective enclosures only feed from stations where it is not required to read.

4 Divert and continue and Divert and stop features are mutually exclusive.

5 The minimum marks in Level 1 are: Start mark + accumulate or insert. That is 2 marks in total. However, it is highly recommended to add a third mark, the safety mark in the minimum configuration.

6 The selective feed marks are always present on the last page of a set.

7 The system always starts feeding pages from the reading feeder, before any of the enclosures.

*) Not available from FP.**) USA only.

8.1.12.3 Format of the Marks

Minimum character length: 6.3 mm or 3 characters.

8.1.12.4 Reading Head Location

The reading head is located in the vertical transport area between FE-2 and FE-3. That means that the FPi 4030 can only read from the top feeder.

8.1.12.5 Options

Flexible OMR is also available on the FPi 4030.

Flexible OMR enables the customer to read the OMR codes of differ-ent suppliers. This Means that the system can comprehend and ex-ecute the command in the different codes of for instance Pitney Bowes and/or PFE. The flexible OMR dongles can contain up to 9 different codes.

8.1.13 Product customisation per country / organisation

There is no product customisation per country specific to FPi 4030 except for the usual differences, for example voltage and plugs.



Release: 07/2006
Revision: 0
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Page 8–14


Illustrated parts list

9 Illustrated parts list

Release: 07/2006

This section contains information on the available spare parts. Use the figures and accompanying tables in this section to find the appro-priate part numbers.

NoteEach figure has its own title. Therefore, to quickly find the figure you need, you can refer to the Table of Contents at the front of this manual.

Please noteThe following pages contain a printed version.The current release of the illustrated spare parts list can be looked up online in the Service Knowledge Database (SKD).

Revision: 0

Item number: 51.0067.1001.00 Page 9–1

FPi-4030 Service Manual (Rev.1.2)

Documents

Transcript of FPi-4030 Service Manual (Rev.1.2)