Pitney Bowes DI380 Series Service Manual
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Pitney Bowes DI380 Series Service Manual

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DI380/DI425 Series
Document Inserting Systems
(Includes Secap models SI3300/SI3500)
service Manual
FORM SDT333A (4-06)

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Summary of Contents for Pitney Bowes DI380 Series

  • Page 1 DI380/DI425 Series Document Inserting Systems (Includes Secap models SI3300/SI3500) service Manual FORM SDT333A (4-06)
  • Page 2 The title, copyright and all other proprietary rights in this document are vested in Pitney Bowes Limited and no part of it may be reproduced in any form without the written permission of Pitney Bowes Limited.

  • Page 3: Table Of Contents

    • Contents • Contents Page secTION 1 Introduction 1.1 - Purpose .................... 1.2 - Equipment Covered ................1.3 - Related Publications ................. 1-1/1-2 1.4 - Contents ................... 1.5 - Safety Summary ................1-2/1-3 1.6 - Equipment Safety ................secTION 2 Specifications 2.1 - Material Specification ................
  • Page 4 • Contents Page 4.12- Removing Envelope Feeder (DI425/ SI3500 Only) ......4-11 4.13- Removing Envelope Feed Rollers & Separator Pad (DI425/SI3500 Only) ....................4-11 4.14- Removal of Flapper Assembly and Blade ..........4-12 4.15- Removal of the Transport Pivot Plate & Insertion Roller ...... 4-13 4.16- Removal of Sealer Rollers ..............
  • Page 5 • Contents Page 6.7- BOC-(NOT) AND EOC-(NOT) ............6.8- Parity and Other Checks ..............6.9- Retime Marks ................... 6.10- Allowable Mark Combinations ............6.11- Enhanced OMR ................6-10 6.12- Auto-Batch ..................6-10 6.13- Selective Insertion ................6-10 6.14- Wrap-Around Sequence ..............6-10 6.15- Wrap Around Sequence Marks ............
  • Page 6 • Contents Page 7.3.5 Test A.C. Motor 7.3.6 Run Test Cycle 7.3.7 Test Display 7.3.8 Test Clutch and A.C. Motor 7.3.9 Test OMR Sensors 7.3.10 Test Service Counter 7.3.11 Test Interlock Relay 7.3.12 Test DDD Calibration 7.3.13 Select Board Type 7.3.14 Test Memory 7.4-...

  • Page 7: Introduction

    DI380 Operating Guide Hungarian SDC648 DI380 Operating Guide Portuguese SDC649 DI380 Operating Guide Spanish SDC650 DI380 Operating Guide French (Pitney Bowes Branded) SDC1069 DI380 Operating Guide French (Secap Groupe PB Branded) SDC651 DI380 Operating Guide Polish SDC730 DI380 Operating Guide Czech...

  • Page 8: Contents

    1 • Introduction SDC1079 SI3300 Operating Guide Italian SDC1080 SI3300 Operating Guide Dutch SDC1081 SI3300 Operating Guide English SDC1082 SI3300 Operating Guide Danish SDC1083 SI3300 Operating Guide French SDC1084 SI3300 Operating Guide German SDC1085 SI3300 Operating Guide Spanish SDC1086 SI3300 Operating Guide German (Hefter Branded) SDT334 DI380/DI425/SI3300/SI3500 Parts List cONTeNTs...
  • Page 9 Introduction • 1 ● When working on a live circuit, use extreme caution. Don’t grasp two sides of a live circuit at the same time. ● Always use the right tools for the job. ● Treat every circuit like a gun which may be loaded. It may not be “live”, but be sure. Check with a neon tester, a voltmeter, or simply unplug the machine.

  • Page 10: Equipment Safety

    1 • Introduction eQUIPMeNT sAFeTY Just by walking around, you yourself may carry a threat to the equipment, in the form of a high voltage electrostatic charge. Your body acts as a giant capacitor which can store large amounts of electricity. Walking across a rug can charge you with several thousand volts, which can discharge in a spark up to an inch long.

  • Page 11: Specifications

    2 • Specifications 2 • Specifications MATeRIAL sPecIFIcATIONs sheet Feeders Minimum sheet size: 127mm Width 127mm Length Maximum sheet size: 229mm Width 406mm Length Paper weights: 60g/m Minimum (non OMR) 70g/m Minimum (OMR) 120g/m Maximum Fold configurations: Material length limits before folding Single fold: 127mm - 315mm “C”...
  • Page 12 The envelope Stacker can accommodate up to 150 filled envelopes. (Dependent on size and contents of the envelope). Material Requirements For best performance, use only materials approved by Pitney Bowes. Materials should be good quality and properly stored. Recommended storage conditions: 18°C (65°F) to 25°C (77°F)
  • Page 13 2 • Specifications envelope Feeder Minimum envelope size: 88mm Depth 220mm Width Maximum envelope size: 164mm Depth WIDTH 242mm Width envelope weights: 65g/m Minimum 100g/m Maximum envelope tray capacity: DI380/SI3300 - Up to a maximum of 100 90g/m envelopes DI425/SI3500 - Up to a maximum of 300 90g/m envelopes end clearance: End clearance between the Insert and envelope is a...

  • Page 14: Machine Specification

    2 • Specifications MAcHINe sPecIFIcATIONs Physical Dimensions DI380/sI3300 DI425/sI3500 Length 773mm 1043mm Depth 568mm 568mm Height 525mm 525mm Weight 55kg 65kg Weight will depend on machine configuration. Weights stated do not include material. Noise Level Running 73dBA electrical 230VAC, 50Hz, 3A or 110VAC, 60Hz, 6A Maximum speed DI380/SI3300 - Up to a maximum of 3,000 cycles per hour...

  • Page 15: Theory Of Operation

    3 • Theory of Operation 3 • Theory of Operation Note: Before any job commences, it is assumed that all the appropriate trays are filled to complete the sequences described below. Please refer to relevant diagrams in section 10- Diagrams INTRODUcTION TO sYsTeM THeORY The DI380/SI3300 and DI425/SI3500 are low volume easy to use Folding/Inserting machines, each available in 3 variants (1, 2 and 3 station machines).

  • Page 16: Single Sheet Feeder Mode & Linked Feeder Mode

    3 • Theory of Operation sINGLe sHeeT FeeDeR MODe & LINKeD FeeDeR MODe When the start button is pressed, the sheet feeder motor (M1) is switched on. This feeds a sheet over the Double Document Detector (DDD1) sensor and stops it, after a counted delay, in the collation nip. This results in the sheet being slightly over driven.

  • Page 17: Flow Diagram- Single Sheet Feeder Mode

    3 • Theory of Operation Sheet Feeder Sheet Feeder Envelope Motor M9 Motor M2 (OP10) Motor M1 (OP9) Sheet Feeder Sheet Feeder Envelope Sensor S1 DDD 2 Sensor DDD 1 Sensor Lead Edge Sensor S2 Stop Delay Collation Motor Stop Fold Plate 2 Sensor OP14 Insertion Solenoid L1...

  • Page 18: Insert Feeder Mode

    3 • Theory of Operation INseRT FeeDeR MODe When the start button is pressed, two motors control the transport of the insert. The insert pre-feeder motor (M3) is energized and feeds a single insert past the Double Document Detection (DDD3) sensor. If a double is detected, the machine will stop and the double insert symbol will be indicated on the control panel.

  • Page 19: Flow Diagram- Insert Feeder Mode

    3 • Theory of Operation Insert Pre-Feed Envelope Motor M9 Motor M3 Insert Envelope Sensor S1 DDD 3 Sensor Lead Edge Sensor S2 Stop Delay Insert Collation Motor Stop Insertion Solenoid L1 Hold Down Solenoid Transport Pivot Plate Unblocked/Blocked Sensor OP5 Shoe Horn Solenoid L3 ON Finger Solenoid L4...

  • Page 20: Two Sheet Feeder Mode

    3 • Theory of Operation TWO sHeeT FeeDeR MODe When the start button is pressed, the sheet feeder motor (M1) is switched on. This feeds a sheet over the Double Document Detector (DDD1) sensor. This triggers sheet feeder motor (M2) to feed a sheet up to the Double Document Detector (DDD2).

  • Page 21: Flow Diagram- Two Sheet Feeder Mode

    3 • Theory of Operation Sheet Feeder Sheet Feeder Envelope Motor M9 Motor M1 Motor M2 Sheet Feeder Sheet Feeder Envelope Sensor S1 DDD 1 Sensor DDD 2 Sensor Lead Edge Sensor S2 Stop Delay Collation Motor Stop Fold Plate 2 Insertion Solenoid L1 Sensor OP14 Hold Down Solenoid...

  • Page 22: Single Sheet Feeder Plus An Insert Mode

    3 • Theory of Operation sINGLe sHeeT FeeDeR PLUs AN INseRT MODe When the start button is pressed two motors control the transport of the insert. The insert pre-feeder motor (M3) is energized and feeds a single insert past the Double Document Detection (DDD3) sensor. If a double is detected, the machine will stop and the double insert symbol will be indicated on the control panel.

  • Page 23: Flow Diagram- Single Sheet Feeder Plus An Insert Mode

    3 • Theory of Operation Insert Pre-Feed Sheet Feeder Envelope Motor M9 Motor M3 Motor M1 Insert Feeder Sheet Feeder Envelope Sensor S1 DDD 3 Sensor DDD 1 Sensor Lead Edge Sensor S2 Stop Stop Insert Motor Collation Motor Delay Delay Stop Fold Plate 2...

  • Page 24: Two Sheet Feeders Plus An Insert Mode

    3 • Theory of Operation TWO sHeeT FeeDeRs PLUs AN INseRT MODe When the start button is pressed. The insert pre-feeder motor (M3) is energized and feeds a single insert past the Double Document Detection (DDD3) sensor. If a double is detected, the machine will stop and the double insert symbol will be indicated on the control panel.

  • Page 25: Flow Diagram- Two Sheet Feeders Plus An Insert Mode

    3 • Theory of Operation Insert Pre-Feed Sheet Feeder Sheet Feeder Envelope Motor M9 Motor M3 Motor M1 Motor M2 Insert Feeder Sheet Feeder Sheet Feeder Envelope Sensor S1 DDD 3 Sensor DDD 1 Sensor DDD 2 Sensor Lead Edge Sensor S2 Stop Stop Insert Motor...

  • Page 26: The Fold Only Mode

    3 • Theory of Operation THe FOLD ONLY MODe When the start button is pressed, the sheet feeder motor (M1) is switched on. This feeds a sheet over the Double Document Detector (DDD1) sensor. The sheet stops, after a counted delay, in the collation nip.

  • Page 27: Flow Diagram- The Fold Only Mode

    3 • Theory of Operation Sheet Feeder Motor M1 Sheet Feeder DDD 1 Sensor Stop First cycle does not Collation Motor stop at the collation motor. Fold Plate 2 Sensor OP14 Transport Pivot Plate Unblocked/Blocked Sensor OP5 Finger Solenoid L4 Sealer Solenoid L5 Moistener Sensor (Software Counter) S3...

  • Page 28: Accumulation From Main Sheet Feeder

    3 • Theory of Operation AccUMULATION FROM MAIN sHeeT FeeDeR After a trial piece has been processed and the start button is pressed, the sheet feeder motor (M1) is switched on. This feeds a sheet over the Double Document Detector (DD1) sensor and stops it, after a counted delay, in the collation nip.

  • Page 29: Flow Diagram- Accumulation For Sheet Feeder 1 Mode

    3 • Theory of Operation Sheet Feeder Motor Envelope Motor M9 M1 (OP9) Envelope Sensor S1 Sheet Feeder DDD1 Sensor Stop Lead Edge Sensor S2 Collation Motor M5 Delay Fold Plate 2 Sensor OP14 Stop Insertion Solenoid L1 Transport Pivot Plate Unblocked/Blocked Hold Down Solenoid Sensor OP5...

  • Page 30: Double Detect Sensors

    3 • Theory of Operation DOUBLe DeTecT seNsORs only adjustable in the service parameters screen and are not operator selectable. This is to allow the engineer to choose different detection reference points to suit the customer’s application. Sheet Feeder 1 and Sheet Feeder 2 have three positions available: LEAD, MIDDLE and TRAIL. The Insert feeder has only the one option: LEAD.

  • Page 31: Ac Motor

    3 • Theory of Operation 3.10 Ac MOTOR The machines are fitted with a capacitor start motor which is driven using two solid-state relays (SSR's). Use of a motor start capacitor means the machine can only be started once every 17 seconds on average, hence the fitting of the hand crank to assist in the retrieval of jammed material.
  • Page 32 3 • Theory of Operation 3-18 SDT333A DI380/DI425/SI3300/SI3500 Service Manual...

  • Page 33: Removal & Replacement

    4 • Removal & Replacement 4 • Removal & Replacement ReMOVING cOVeRs AND P.c.B covers Disconnect power from the machine before attempting to remove the covers. Remove all trays, feeders and both fold plates. Remove all the metal and black plastic screws and inserts. Remove all covers except moistener cover.

  • Page 34: Removing Sheetfeeder Separator Roller & Pad

    4 • Removal & Replacement ReMOVING sHeeTFeeDeR sePARATOR ROLLeR & PAD Follow instruction for cover removal in section 4.1. Disconnect the following connectors on or near the motor bracket assembly: P19A, P19C, P19D, P20A, P20B, P20D and P20E. Remove 3 screws from the sheet feeder motor bracket and carefully remove bracket.

  • Page 35: Removing Carriage Assembly

    4 • Removal & Replacement ReMOVING cARRIAGe AsseMBLY Follow instruction for cover removal in section 4.1. Disconnect connector P23C on rear side. Remove the 2 holding plates (see illustrations) and screws on both the front and rear sides of the machine.

  • Page 36: Removal Of Lower Collation Roller

    4 • Removal & Replacement ReMOVAL OF LOWeR cOLLATION ROLLeR The machine should be in a half fold mode before the lower collation rollers can be removed. This allows easier access to the half fold deflector assembly. Follow instruction for cover and PCB removal in section 4.1. Follow instruction for removing sheet feeder motor bracket assembly section 4.3 steps 1-3.

  • Page 37: Removal Of Upper Insert Drive Rollers

    4 • Removal & Replacement ReMOVAL OF UPPeR INseRT DRIVe ROLLeRs Follow instruction for cover and PCB Motor Bracket removal in section 4.1. Remove insert feeder assembly. Cable Tie Remove the insert feeder motor bracket held by 3 screws. Remove the E-clips, white gear and pin from behind the insert feeder motors brackets.
  • Page 38 4 • Removal & Replacement Remove 4 fold roller springs on the front and rear side of the machine, taking note of the position of the different strength springs. Care should be exercised when removing these springs. Remove 4 E-clips and bearings from the front side.

  • Page 39: Dismantling Insert Feeder (Di380/Si330 Only)

    4 • Removal & Replacement DIsMANTLING INseRT FeeDeR (DI380) ONLY Remove insert feeder. Detach wedge from feeder Unscrew the 4 screws holding the top cover from the insert feeder tray. Remove the four screws holding the side walls to the tray. Remove the single screw and washer holding the blue adjustment arm.

  • Page 40: Dismantling Insert Feeder (Di425/Si3500 Only)

    4 • Removal & Replacement DIsMANTLING INseRT FeeDeR (DI425/sI3500) Remove insert feeder. Detach wedge from feeder Unscrew the 4 screws holding the top cover from the insert feeder tray and remove top cover. Turn the whole unit over onto its' back. Remove 4 screws from the bottom tray which are holding the side walls to the tray.

  • Page 41: Removal Of Top Assembly

    4 • Removal & Replacement 4.10 ReMOVAL OF TOP AsseMBLY Follow instruction for cover and PCB removal in section 4.1. Disconnect counter connector P28K at the AC hand crank. Undo the belt tension next to the hand crank gearing and remove the drive belt. Remove fold plate 1 motor (M6) held by 3 screws and an E-clip and washer on the drive pulley shaft.

  • Page 42: Removal Of Envelope Feed Rollers And Separator Pad (Di380/Si330 Only)

    4 • Removal & Replacement 4.11 ReMOVAL OF eNVeLOPe FeeD ROLLeRs AND sePARATOR PAD (DI380/sI3300 ONLY) Remove the lower left hand (envelope feeder Pre Feed Shaft area) covers from the front and rear side of 3 E-clips and E-clip the machine. White Gear Unclip the cover from the envelope flap deflector and unclip the out of paper...

  • Page 43: Removing Envelope Feeder (Di425/Si3500 Only)

    4 • Removal & Replacement 4.12 ReMOVING eNVeLOPe FeeDeR (DI425/sI3500 ONLY) Remove envelope feeder covers. Disconnect wiring for Upper and Lower Limit Sensors, (IL13 & IL14) at the rear of the machine, and also the earth strap at the front of the machine. Release tensioner (A) on Envelope Platform Motor drive belt, and remove.

  • Page 44: Removal Of Flapper Assembly And Blade

    4 • Removal & Replacement 4.14 ReMOVAL OF FLAPPeR AsseMBLY AND BLADe Flapper Assembly Follow instruction for cover and PCB Hinge Screw (1 each side) removal in section 4.1. Remove the 2 screws on the hinge on the front and rear sides. Take care not to drop the spacers.

  • Page 45: Removal Of The Transport Pivot Plate & Insertion Roller

    4 • Removal & Replacement 4.15 ReMOVAL OF THe TRANsPORT PIVOT PLATe & INseRTION ROLLeR Follow instruction for cover and PCB removal in section 4.1. Shoe Horn Follow instruction for top assembly removal Shaft Screw in section 4.9. Remove the 2 screws that hold the shoe horn shaft assembly in place and remove shaft from the base.

  • Page 46: Removing The Inverter Motor Assembly

    4 • Removal & Replacement 4.17 ReMOVAL THe INVeRTeR MOTOR AsseMBLY Disconnect power. Remove the 8 screws from the inverter ramp (4 long and 4 short). Note: Access is now gained to the motor and encoder board. (If the plastic bearings are removed via the motor and encoder, make sure the bearings are correctly located on reassembly).

  • Page 47: Removing Lower Flapper Rollers

    4 • Removal & Replacement 10. On the arching roller, push the rearmost bobbin off the pin. 11. Remove E-clips and bearings from front and rear sides holding the arch roller. 12. Withdraw the arching roller from the base by tilting it upwards at the front end. 13.

  • Page 48: Removal Of The Lower Envelope Drive Roller

    4 • Removal & Replacement 12. Disconnect power supply cable TB4. Cable TB4 13. Remove 2 screws from power supply (top and bottom on right side of Power Supply Unit) and pivot the unit to gain access to the roller. 14.

  • Page 49: Removal Of The Power Supply Unit And Ac Motor

    4 • Removal & Replacement 4.21 ReMOVAL OF THe POWeR sUPPLY UNIT AND Ac MOTOR Follow instructions for the removing all covers only, in section 4.1 steps 1-6. Undo the E.I.U. port connector from the logic board. Drain the water from the sealer unit. Undo the screws holding the AC motor cover.
  • Page 50 4 • Removal & Replacement 4-18 SDT333A DI380/DI425/SI3300/SI3500 Service Manual...

  • Page 51: Adjustments

    5 • Adjustments 5 • Adjustments eNVeLOPe FeeD TRAY GUIDes (DI380/sI3300 ONLY) Wind Leadscrew so that side guides are at the middle of the tray. Loosen the Knurled Locking Nut and adjust the Bias Adjustment Nut until the guides are of equal distance from the central raised tray area.

  • Page 52: Envelope Separator Pad Side To Side Adjustment

    5 • Adjustments eNVeLOPe sePARATOR PAD sIDe TO sIDe ADJUsTMeNT Loosen the two screws holding the Separator Pad. Adjust the Separator Pad front to back so that it is centralised to the Separator Roller. Separator Rollers Separator Pad Envelope Separator Pad Adjustment eNVeLOPe sePARATOR PAD HeIGHT (DI380/sI3300 ONLY) Loosen the screws which hold the Separator Bracket to both side frames.

  • Page 53: Envelope Separator Pad Height (Di425/Si3500 Only)

    5 • Adjustments eNVeLOPe sePARATOR PAD HeIGHT (DI425/sI3500 ONLY) Loosen the Envelope Separator Pad Adjustment screw A. Adjust the bracket until a gap of 6mm is achieved between the Separator Pad and Separator Roller. A 6mm Allen Key may be used to check the height. Tighten the Separator Pad Adjustment screw.

  • Page 54: Insertion Flipper Actuation Height/ Hold Down Solenoid Adjustment

    5 • Adjustments INseRTION FLIPPeR AcTUATION HeIGHT/ HOLD DOWN sOLeNOID ADJUsTMeNT Loosen the Hold Down Solenoid mounting screws (A) slightly. Depress the plunger of the hold down solenoid (L2) so that the hold down fingers pivot the flippers. Move the hold down solenoid in its slots until the flippers raise to a height of 7mm above the deck measured from the points shown in the diagram.

  • Page 55: Insertion Hold Down Finger Rest Position

    5 • Adjustments INseRTION HOLD DOWN FINGeR ResT POsITION Adjust the Limit Stop Screw (A) so that Limit Stop a gap of 1mm is achieved between the Screw A Insertion Shaft and the top side of the Hold Down Fingers. Insertion Shaft Hold Down Fingers...

  • Page 56: Transport Pivot Plate Setting

    5 • Adjustments TRANsPORT PIVOT PLATe seTTING Before performing this adjustment, the transport plate must be central and free moving, as described in section 5.8 above. sTeP 1 Remove Opto Bracket (Setting Gauge) from front frame. Release screw ‘A’ and move limit plate fully up. Position the gauge in between the insertion shaft and transport plate centre spring.
  • Page 57 5 • Adjustments 5.10 FOLD PLATes 1 AND 2 OFFseT It may be necessary to set an offset 96mm value for each Fold Plate in order to Fold 1 make actual fold panel sizes agree with the dimensions indicated on the 196mm machine’s display in setup.

  • Page 58: Nesting Constant

    5 • Adjustments 5.11 NesTING cONsTANT B e f o r e p r o c e e d i n g w i t h t h i s adjustment, check that the Fold Offset is set correctly as described in section 5.10.

  • Page 59: Q Station Calibration

    5 • Adjustments 5.12.2 Q station calibration Q Station Alignment must be completed before carrying out this adjustment. Refer to the illustration below. Enter the ‘Set Parameters’ menu on the display. Choose ‘Q Station Calibration - Finger Stop’. A value of 130mm ±2 will be displayed. Place an envelope into the Q Station, ensuring that the lead edge of the envelope is touching the Finger Stops.

  • Page 60: Q Station Height

    5 • Adjustments 5.12.3 Q station Height This adjustment allows the height of the Q Station to be adjusted to aid in the insertion of different thickness’ of collation, and to prevent overdrive of the envelope during the insertion process. Loosen the two Q Station height adjustment screws.

  • Page 61: Insert Feeder Adjustments

    5 • Adjustments 5.13 INseRT FeeDeR ADJUsTMeNTs Carry out Insert Feeder adjustments in the following order: 5.13.1 separator Roller Alignment Ensure the Separator Rollers are adjusted side to side so that they are centralised with the cut-outs of the Separator Stone.
  • Page 62 5 • Adjustments Set Stone to position “A”. Set to position D Set lever to position D DI380/SI3300 DI425/SI3500 Separator Stone Setting Loosen the allen screw locking the Separator Thumbwheel. Insert a sheet of 80 g/m paper under the Separator Rollers. Adjust the Separator Knob until you feel a slight drag on the paper, without scoring.

  • Page 63: Separator Pre-Feed Height (Di380/ Si330 Only)

    5 • Adjustments 5.13.3 separator Pre-Feed Height (DI380/sI3300 Only) Move the Detent setting to the middle (position 5) setting. Middle Position Detent Setting Loosen adjusting screw (A) until the Pre-Feed Rollers fall and touch the deck. Turn knob (B) fully open. Knob (B) Adjusting screw (A) Separator Pre-Feed Adjustment Points...

  • Page 64: Skew Adjustment

    5 • Adjustments 5.14 sKeW ADJUsTMeNT Skew adjustment has been incorporated into the machine to enable a badly skewed document (outside skew tolerance of 1.6mm) to be folded squarely. To set the skew adjustment to central position, the following steps should be carried out: Loosen the fixing screw.

  • Page 65: Flapper Adjustment

    5 • Adjustments 5.15 FLAPPeR ADJUsTMeNT Cover locating screws Remove the flapper assembly cover, (four screws). Flapper Assembly Cover Loosen the adjustment plate screws, (2 each side). DO NOT REMOVE. Adjustment Plate screws Adjustment Plate Screws Place 0.5 to 0.8mm spacers (5 to 8 strips of 80g/m paper) on Rotate Flapper Blade...
  • Page 66 5 • Adjustments 5-16 SDT333A DI380/DI425/SI3300/SI3500 Service Manual...

  • Page 67: Omr

    6 • OMR OMR• 6 A BRIeF OVeRVIeW OF OMR ON THIs sYsTeM OMR sensors are fitted to the sheet feeders and are mounted within the machine case. They are easily adjustable for the following paper sizes: • 8 inch wide •...

  • Page 68: Omr Specifications

    6 • OMR OMR sPecIFIcATIONs The mark must be a solid black line between 1pt and 2pts thick (0.35mm to 0.7mm) and at least 10mm wide. The marks should be printed on white paper. The paper weight should be between 70-90gsm. The maximum total compressed thickness of the outer envelope should not exceed 2mmm.

  • Page 69: Standard' Omr Positions Diagram

    OMR• 6 ‘Standard’ OMR Positions 54mm Feed Direction for Top Scanning 96mm (C and Double Fold) 115mm 20mm Clear Zone 20mm x 115mm min Clear Zone 20mm x 100mm min 20mm Vertically centre group within area indicated 100mm Feed Direction for 69mm Bottom Scanning (Z and Single Fold)

  • Page 70: Offset' Omr Positions

    6 • OMR ‘Offset’ OMR Positions Feed Direction for 20mm Top Scanning 95mm (C and Double Fold) 40mm 125mm 65mm 65mm Bench Mark 115mm 80mm 20mm Feed Direction for Bottom Scanning (Z and Single Fold) OMR marks should be positioned as follows: ‘C’...

  • Page 71: Swis Offset' Omr Positions

    OMR• 6 ‘Swiss Offset’ OMR Positions Feed Direction for 20mm Top Scanning 95mm (C and Double Fold) 40mm 125mm 65mm 65mm Bench Mark 165mm 130mm 20mm Feed Direction for Bottom Scanning (Z and Single Fold) OMR marks should be positioned as follows: ‘C’...
  • Page 72 6 • OMR To change from ‘Normal Offset’ to ‘Swiss Offset’ simply enter service parameters and scroll through until OMR Offset Feeder 2 is displayed. This value should be 115 for ‘Normal Offset’ and 165 for ‘Swiss Offset’. Any other values entered here are not supported and may cause scanning issues. NOTE: Select Feed cannot be used when using ‘Offset’...

  • Page 73: Omr Mark Grouping

    OMR• 6 OMR MARK GROUPING Each OMR code begins with two fixed marks at the end nearest to the sensor (Benchmark and Safety mark). These are followed by one, two, or three groups of marks where each group comprises three data marks followed by a fixed mark. Each data mark is present or absent as required to reflect the desired function.

  • Page 74: Basic Omr

    6 • OMR BAsIc OMR Basic OMR enables you to collate multi-page documents that vary between one and five sheets (10 sheets with Single fold and certain paper weights). It allows you to vary the number of pages per envelope in a run from envelope to another through the use of OMR marks based on the document information in the customer’s database.

  • Page 75: Retime Marks

    OMR• 6 ReTIMe MARKs Retime Marks are necessary for reliable reading of the code, due to the paper speed varying as it feeds. With Basic OMR only the first Retiming mark is needed, if one or both of the other groups are used the Retime Mark associated with that group(s) must also be printed.

  • Page 76: Enhanced Omr

    6 • OMR 6.11 eNHANceD OMR Enhanced OMR allows you to stop feeding sheets at selected points in a run and/or to select whether the other feeders are used—separately for each envelope. It also provides a higher level of mailpiece integrity so that sensitive documents are not sent to the wrong customer. 6.12 AUTO-BATcH Enhanced OMR adds an Auto-Batch mode to supplement the normal OMR batch mode.

  • Page 77: Mark Code Interpretation

    For example, the inserter would stop if the printer had picked up two sheets when printing a page, or if the pages have been disturbed and are out of order, or if the 3 Series picks up two sheets while its double-detect feature is not in use.

  • Page 78: Enabling The Omr Features

    (WAS). These Enhanced features are not accessible and are not displayed in menus for OMR machines configured for Basic OMR. If the customer has purchased the Enhanced OMR option, the Pitney Bowes Service Representa- tive enables the full set of OMR features through the Service Setup menu by entering the passcode 350350 when prompted.

  • Page 79: Scanning Template

    This point must be 75mm ± 5mm from the top of the page > 2nd START action here > Section 7.4.3 of this document shows how to Calibrate the Sensitivity of OMR Form SDT316 RevA (5-02) © Pitney Bowes Limited, 2002 Sensors. Printed in the UK SDT3233A DI380/DI425/SI3300/SI3500 Service Manual 6-13...

  • Page 80: Procedure For Manually Setting The Sensitivity Of The Omr Sensors

    6 • OMR 6.18 PROceDURe FOR MANUALLY seTTING THe seNsITIVITY OF THe OMR seNsORs Introduction It is not normally necessary to change the sensitivity of the OMR scanning sensors on Sheet Feeders 1 and 2, as they are adjusted on the Production line. Should the customer’s application change, whereby the material colour changes or the scanner appears not to function correctly, then it will be necessary to perform the sensitivity adjustment.

  • Page 81: Service Menu & Troubleshooting

    7 • Service Menu & 7 • Service Menu & Troubleshooting Troubleshooting Prior to any fault finding actions the technician should, where possible, check the job settings and materials that are being used with the operator. eNTeRING THe seRVIce MeNU Press the “setup”...

  • Page 82: Set Default Job

    7 • Service Menu & Troubleshooting 7.2.2 set Default Job This sets the Default Job 0 (Zero). 7.2.3 set 50/60Hz To set the frequency of the Mains supply. Factory set. 7.2.4 serial Interface • Meter Interface used for online solutions •...

  • Page 83: Calibrate Q Station

    7 • Service Menu & Troubleshooting 7.2.10 calibrate Q station This is to set the position of the envelope stops. Initially set by the factory. • DI425/SI3500 = 130 • DI380/SI3300 = 130 7.2.11 set Fold Plate Offsets This is to offset the fold panel lengths to match the lengths programmed in by the customer. Initially set by the factory.

  • Page 84: Omr/ Acc Wetter Constant

    7 • Service Menu & Troubleshooting 7.2.18 OMR / Acc Wetter constant This function performs the same function as Basic Wetter Constant, but when OMR/ Acc is used it contacts the envelope earlier to allow for sealing of thicker packages. •...

  • Page 85: Clear Deck Delay

    7 • Service Menu & Troubleshooting 7.2.24 clear Deck Delay The Clear Deck function is inhibited until the Inserting Machine has been stopped for a period of time to ensure that the Mailing Machine has processed all mail and stopped before clear deck is carried out.

  • Page 86: Service Diagnostics

    7 • Service Menu & Troubleshooting seRVIce DIAGNOsTIcs Diagnostics allows the engineer to test every component by using the control panel. Normal state shows the state of the sensors with all feeders and fold plates fitted and with no mate- rial loaded in the machine.

  • Page 87: Test Uart

    7 • Service Menu & Troubleshooting 7.3.2 Test UART This is a Loop Back Test for the RS232 serial port. EIU Use only. 7.3.3 Test D.c. Motors Start Motor To test the motor press “sTART”. “sTART” will switch the motor On and Off. The motor will automatically switch off after 7 seconds.

  • Page 88: Test Solenoids

    7 • Service Menu & Troubleshooting 7.3.4 Test solenoids To test the solenoids, press “sTART” to energise and “sTART” to de-energise. To prevent damage, the solenoid will energise only for a short time. • Finger Solenoid • Insert Solenoid • Shoehorn Solenoid •...

  • Page 89: Select Board Type

    7 • Service Menu & Troubleshooting 7.3.13 select Board Type Manufacturing use only. 7.3.14 Test Memory Manufacturing use only. • Test RAM • Test NVM • Test ROM TROUBLesHOOTING cHARTs 7.4.1 General Information If the customer contacts the service department with an error code, the technician should give information from the ‘Operator Check List’...

  • Page 90: Fault Finding Charts

    7 • Service Menu & Troubleshooting FAULT FINDING cHARTs error codes Operator check List service Diagnostic connector and Replacement and fault Logic Test Parts E01 Fold Plate • Remove fold Plate and Test end stops position 1 not set check for jammed material. Test fold plate sensor P29 pins 6,7,8 Sensor OP13...
  • Page 91 7 • Service Menu & Troubleshooting error codes Operator check List service Diagnostic connector and Replacement and fault Logic Test Parts • Open the flapper cover Test envelope feed sensor P14 pins 18 &19 Replace sensor E11 Envelope and check for any material feeder sensor blocked prior to start of a cycle...
  • Page 92 7 • Service Menu & Troubleshooting error codes Operator check List service Diagnostic connector and Replacement and fault Logic Test Parts E19 Material • Open inverter door and Test exit sensor S4 P35 pins 2 and Replace sensor never entered remove any material and/or left the exit sensor...
  • Page 93 7 • Service Menu & Troubleshooting error codes Operator check List service Diagnostic connector and Replacement and fault Logic Test Parts E24 Insert • Remove material from the Test out of paper sensor P24 pins 4,5,6 Sensor OP11 feeder not fed insert feeder and restart OP11 to roller...
  • Page 94 7 • Service Menu & Troubleshooting error codes Operator check List service Diagnostic connector and Replacement and fault Logic Test Parts E32 Insert • Remove and refit the Test insert feeder sensor P24 pins 8,9 Sensor S12 feeder removed insert feeder tray E33 Envelope •...
  • Page 95 7 • Service Menu & Troubleshooting error codes Operator check List service Diagnostic connector and Replacement and fault Logic Test Parts E44 Feeder • Check the daily mail Visually check that the daily P23 pins 1,2,3 Replace OP3 1 separator switch is properly mail lever is not broken or switch error...
  • Page 96 7 • Service Menu & Troubleshooting error codes Operator check List service Diagnostic connector and Replacement and fault Logic Test Parts E57 Sheet • Adjust the sheet feeder Check the condition of the Replace the Feeder 2 fail to side guides alignment by separator roller and pad.
  • Page 97 7 • Service Menu & Troubleshooting error codes Operator check List service Diagnostic connector and Replacement and fault Logic Test Parts E61 Stream • Check that the material Check the material is within Separator roller feed on sheet is not sticking together. spec.
  • Page 98 7 • Service Menu & Troubleshooting error codes Operator check List service Diagnostic connector and Replacement and fault Logic Test Parts E72 Envelope • Check envelope feeder is Check envelope platform Feeder not over-filled. upper limit switch IL13 and Overloaded envelope present sensor (DI425/SI3500 PS11.
  • Page 99 7 • Service Menu & Troubleshooting error codes Operator check List service Diagnostic connector and Replacement and fault Logic Test Parts OMR sensor possibly faulty • The code does not have E87 OMR or needs calibrating. an EVEN number of Parity Error marks.
  • Page 100 7 • Service Menu & Troubleshooting error codes Operator check List service Diagnostic connector and Replacement and fault Logic Test Parts • Remove mail from the E115 VPS stacker, then press start. Nearly Full • Pull VPS to un-docked E116 VPS Cam Possible motor bind.
  • Page 101 7 • Service Menu & Troubleshooting error codes Operator check List service Diagnostic connector and Replacement and fault Logic Test Parts E126 Processor • Power off/ Power on. Reset SDT333A DI380/DI425/SI3300/SI3500 Service Manual 7-21...
  • Page 102 7 • Service Menu & Troubleshooting 7-22 SDT333A DI380/DI425/SI3300/SI3500 Service Manual...

  • Page 103: Preventive Maintenance

    8 • Preventive Maintenance Preventive Maintenance • 8 GeNeRAL INFORMATION Servicing has been broken down into service procedures at 100,000 cycle and 200,000 cycle intervals, so that the following items are either checked, cleaned or replaced. Reflective and DDD sensors must be cleaned on every 'E' call. Before attempting to service this equipment discuss with the operator any operational problems.

  • Page 104: The 200K Service

    8 • Preventive Maintenance THe 200K seRVIce Check that all material falls within specification. Check operation of equipment. Check operation of safety interlocks. Listen for any unusual noises. Visually check for any loose or detached parts. Remove Feeder Trays, Fold Plates and Insert Feeder assembly. Remove all covers, front and rear.

  • Page 105: Installation

    9 • Installation 9 • Installation UNPAcK AND cHecK Unpack and check machine for damage. Locate the machine on a strong, level table adjacent to a power socket. Allow clearance for the stacker to locate over the right-hand edge of the table. Remove the tywrap from the Q Station.

  • Page 106: Operator Training

    9 • Installation OPeRATOR TRAINING Show and explain the machine layout and the functions of all the blue knobs, including: • Daily Mail (Manual Feed) Lever • Feeder Trays • Fold plates • Stacker Switch the machine on. Explain the functions of the Display Panel, its symbols and buttons. Show how to select a pre-programmed job.

  • Page 107: Flow Diagrams

    10 • Diagrams 10 • Diagrams 10.1 FLOW DIAGRAMs INSERT FEEDER SHEET FEEDER 1 INSERT FEEDER SHEET FEEDER 1 SHEET FEEDER 2 SHEET FEEDER 2 FOLD PLATE 1 FOLD PLATE 1 CARRIAGE FOLD PLATE 2 ASSEMBLY CARRIAGE FOLD PLATE 2 ASSEMBLY Q STATION Q STATION...

  • Page 108: Component Locations

    10 • Diagrams 10.2 cOMPONeNT LOcATIONs OP11 Not present on system but included for backwards compatibility. OP10 Not present on system but included for backwards compatibility. OP13 OP12 OP14 Not present on system but included for backwards compatibility. OP15 Motor DI380/SI3300 OP11 Not present on system but...

  • Page 109: Switches, Sensors, Motors, Solenoids Test Levels

    10 • Diagrams 10.3 sWITcHes, seNsORs, MOTORs, sOLeNOIDs TesT LeVeLs Mechanical switches PIN Location Wires Open closed Location Top Cover 15, 16, 17, 18 Fold Plate 1 Interlock 10, 11, 12, 13 Black 24V (high) 24V (high) Fold Plate 2 Interlock 10, 11, 12, 13 Yellow 0V (low) 24V (high) Flapper Interlock...
  • Page 110 10 • Diagrams Magnetic Reed switches PIN Location Wires Blocked Unblocked Location Black 0V (low) 0V (low) Envelope Feed S1 18, 19 White 0V (low) 5V (high) Lead Edge 11, 12 Moistener 2, 3 Yellow 5V (high) 0V (low) Exit 9, 10 White 0V (low)
  • Page 111 10 • Diagrams Through Beam sensor PIN Location Wires Blocked Unblocked Location Envelope Present Sensor PS11 1, 3, 5 Yellow 5V (high) 5V (high) Envelope Platform Upper Limit IL13 8, 10, 12 White 0V (low) 5V (high) Envelope Platform Lower Limit IL14 2, 4, 6 Black 0V (low)
  • Page 112 10 • Diagrams PcB Test Points Location 3.3 Volts 1.2 Volts Location 5 Volts Indicator 24 Volts Indicator 3.3 Volts Indicator CR57 Micro Diagnostics Factory Use Only CR58 FPGA Indicator Flashes if OK CR61 Software Control Panel RS232 Counter OMR Sensors Not Used (Software Diagnostics) Not Used (Software Diagnostics) 10-6...

  • Page 113: Pcb Layout

    10 • Diagrams 10.4 PcB LAYOUT CR57 CR58 CR61 SDT333A DI380/DI425/SI3300/SI3500 Service Manual 10-7...

  • Page 114: Drive Belt Routing

    10 • Diagrams 10.5 DRIVe BeLT ROUTING Rear View Front View 10-8 SDT333A DI380/DI425/SI3300/SI3500 Service Manual...

  • Page 115: Schematic - Insertion/Moistener/Exit Areas

    10 • Diagrams 10.6 scHeMATIc - INseRTION/MOIsTeNeR/eXIT AReAs SDT333A DI380/DI425/SI3300/SI3500 Service Manual 10-9...

  • Page 116: Schematic- Sheet Feeders/ Collation Motor

    10 • Diagrams 10.7 scHeMATIc - sHeeT FeeDeRs/cOLLATION MOTOR 10-10 SDT333A DI380/DI425/SI3300/SI3500 Service Manual...

  • Page 117: Schematic- Fold Plates/ Half Fold

    10 • Diagrams 10.8 scHeMATIc - FOLD PLATes/HALF FOLD SDT333A DI380/DI425/SI3300/SI3500 Service Manual 10-11...

  • Page 118: Schematic- Envelope Feeder/ Ac Hand Crank (Manual Advance)

    10 • Diagrams 10.9 scHeMATIc - eNVeLOPe FeeDeR/Ac HAND cRANK (MANUAL ADVANce) 10-12 SDT333A DI380/DI425/SI3300/SI3500 Service Manual...

  • Page 119: Schematic- P40 Envelope Platform Connector (Di425/Si3500)

    10 • Diagrams 10.10 scHeMATIc - P40 eNVeLOPe PLATFORM cONNecTOR (DI425/sI3500) Envelope Sensor 200-7010 Envelope Platform Down Sensor F382323 Envelope Platform Up Sensor F382323 Platform pushbutton Polarising Key 10.11 scHeMATIc - P41 eNVeLOPe PLATFORM MOTOR cONNecTOR (DI425/sI3500) yellow Platform Stepper Motor orange NX00418 (M20)

  • Page 120: Schematic- Insert Feeder

    10 • Diagrams 10.12 scHeMATIc - INseRT FeeDeR 10-14 SDT333A DI380/DI425/SI3300/SI3500 Service Manual...

  • Page 121: Schematic- Display/ Psu

    10 • Diagrams 10.13 scHeMATIc - DIsPLAY/PsU SDT333A DI380/DI425/SI3300/SI3500 Service Manual 10-15...

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Di425 seriesSi3300Si3500

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