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Plockmatic 45 Service Manual

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Mailer/Inserter Model 45
Service Manual
February 2004
Part No. 45526

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Summary of Contents for Plockmatic 45

  • Page 1 Mailer/Inserter Model 45 Service Manual February 2004 Part No. 45526...

  • Page 3: Table Of Contents

    Contents T08090 Page Directions of the Model 45 September -98 iiii Special Tools iiii September -98 Covers REP 2.1 Front and rear cover 2.1.1 September -98 REP 2.2 Infeed cover 2.2.1 September -98 REP 2.3 Outfeed cover 2.3.1 January -04 Main components REP 3.1...
  • Page 4 FIP 11.2 Trouble shooting February -04 11.3.1 FIP 11.3 Principle of Operation February -04 * If this document is a pdf file, the Wiring diagram and Electrical component location is a separate file, T08090a. MAIL INSERTER MODEL 45 PAGE JUN -00...

  • Page 5: Directions Of The Model

    Directions of the Model 45 T08090 Rear side Left side Right side Front side MAIL INSERTER MODEL 45 PAGE SEP -98...

  • Page 6: Iiii Special Tools Iiii

    Special Tools T08090 In order to facilitate the service of the Model 45 there are a few special tools available. Processor extractor tool. Part No. 95147 Cheater plug. Part No. 451003. To simulate envelope feeding table closed. ESD Ground strap. Part No. 901044.

  • Page 7: Rep 2.1 Front And Rear Cover

    REP 2.1 Front and rear cover T08090 The front and rear cover is fastened to the Model 45 with hooks at the bottom edge and a screw. REAR COVER REMOVAL Switch off the main power switch and disconnect the power cord.

  • Page 8: Rep 2.2 Infeed Cover

    1. Switch off the main power switch and disconnect the power cord. 2. Loosen the four screws (1). 3. Slide the cover to the right and remove the cover. INSTALLATION Installation is an exact reversed procedure of removal. MAIL INSERTER MODEL 45 PAGE 2.2.1 SEP -98...

  • Page 9: Rep 2.3 Outfeed Cover

    Open the outfeed cover. Lift the clips over the receiving tray (2) bars while pulling the tray out. Remove the outfeed cover (1). INSTALLATION Installation is an exact reversed procedure of removal. MAIL INSERTER MODEL 45 PAGE 2.3.1 JAN -04...

  • Page 10: Rep 3.1 Removing The Envelope Feeding Table

    REP 3.1 Removing the envelope feeding table T08090 The envelope feeding table is mounted on a slide bar screwed on to the Model 45 frame with four screws. REMOVAL Switch off the main power switch and disconnect the power cord.

  • Page 11: Rep 3.2 Removing The Document Feeding Unit

    REP 3.2 Removing the document feeding unit T08090 The document feeding unit is mounted on to the Model 45 frame with two screws. REMOVAL Switch off the main power switch and disconnect the power cord. 2. Remove the rear and front cover according to REP 2.1.

  • Page 12: Rep 3.3 Draining The Sealing System

    1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 INSTALLATION Installation is an exact reversed procedure of removal. MAIL INSERTER MODEL 45 PAGE 3.3.1 JAN -04...
  • Page 13 Connect the power cord. Enter the service mode according to section 9.1. Run motor M9 for a couple of seconds according to section 9.3. Check that the cloth on the wetting roller is soaked. MAIL INSERTER MODEL 45 PAGE 3.3.2 JAN -04...

  • Page 14: Rep 4.1 Out Of Envelope Sensor (Sen1)

    7. Remove the sensor. INSTALLATION Installation is an exact reversed procedure of removal. ADJUSTMENT Adjust the sensor so it activates when the sensor actuator arm is 1.5 - 2 mm from the frame. MAIL INSERTER MODEL 45 PAGE 4.1.1 JUL -99...
  • Page 15 PAGE INTENTIONALLY BLANK...

  • Page 16: Rep 4.2 Envelope Position 2 Sensor (Sen2)

    T08090 SEN2, PHOTO TRANSISTOR The SEN2 photo transistor is mounted on a plate located under the envelope feeding cover inside the Model 45. REMOVAL 1. Switch off the main power switch and disconnect the power cord. 2. Slide the envelope feeding table open to access the photo transistor (1).
  • Page 17 5. Fold down the cover plate and notice the position of the springs. 6. Remove the LED bracket. 7. Remove the LED (2). INSTALLATION Installation is an exact reversed procedure of removal. purple wire black wire MAIL INSERTER MODEL 45 PAGE 4.2.2 SEP -98...

  • Page 18: Rep 4.3 Envelope Position 3 Sensor (Sen3)

    T08090 SEN3, PHOTO TRANSISTOR The SEN3 photo transistor (1) is mounted on a plate located under the envelope feeding cover inside the Model 45. REMOVAL 1. Switch off the main power switch and disconnect the power cord. 2. Remove the document feeding unit according to REP 3.2 to access the photo transistor.
  • Page 19 Open the envelope feeding cover. 4. Remove the SEN3 LED cover (1). Remove the LED bracket. Remove the LED. INSTALLATION Installation is an exact reversed procedure of removal. orange wire brown wire MAIL INSERTER MODEL 45 PAGE 4.3.2 SEP -98...

  • Page 20: Rep 4.4 Envelope Opener Sensor (Sen4)

    1. Switch off the main power switch and disconnect the power cord. 2. Remove the document feeding unit according to REP 3.2. 3. Remove the envelope opener sensor (1). INSTALLATION Installation is an exact reversed procedure of removal. MAIL INSERTER MODEL 45 PAGE 4.4.1 SEP -98...

  • Page 21: Rep 4.5 Envelope Flap Guide Sensor (Sen5)

    Switch off the main power switch and disconnect the power cord. 2. Remove the rear cover according to REP 2.1. Remove the envelope flap guide sensor (1). INSTALLATION Installation is an exact reversed procedure of removal. MAIL INSERTER MODEL 45 PAGE 4.5.1 SEP -98...

  • Page 22: Rep 4.6 Envelope Position Sensor 5 (Sen6) And 4 (Sen7)

    NOTE: Lift the cover plate by the ends in order not to bend it. 4. Remove the photo transistor. INSTALLATION Installation is an exact reversed procedure of removal. grey wire white wire MAIL INSERTER MODEL 45 PAGE 4.6.1 SEP -98...
  • Page 23 Switch off the main power switch and disconnect the power cord. Remove the document feeding unit according to REP 3.2. 3. Remove the sensor (1). INSTALLATION Installation is an exact reversed procedure of removal. purple wire black wire MAIL INSERTER MODEL 45 PAGE 4.6.2 SEP -98...

  • Page 24: Rep 3.2

    Installation is an exact reversed procedure of removal. blue wire SEN8, photo transistor yellow wire orange wire SEN8, LED brownwire grey wire SEN9, photo transistor white wire purple wire SEN9, LED black wire MAIL INSERTER MODEL 45 PAGE 4.7.1 SEP -98...

  • Page 25: Rep 4.8 Envelope Receiving Tray Sensor (Sen10)

    10. Tilt the water container and remove the two screws behind the container holding the sensor bracket on the front side. 11. Remove the sensor bracket. 12. Remove the sensor. INSTALLATION Installation is an exact reversed procedure of removal. MAIL INSERTER MODEL 45 PAGE 4.8.1 SEP -98...

  • Page 26: Rep 4.9 Interlock Switch 1 (Sw15)

    Cut off the wires close to the jack and strip the wires so they can be mounted in the terminal block that comes with the spare part jack. Remove the jack. INSTALLATION Installation is an exact reversed procedure of removal. MAIL INSERTER MODEL 45 PAGE 4.9.1 JAN -04...

  • Page 27: Rep 4.10 Interlock Switch 2 (Sw16)

    4. Remove the switch bracket. 5. Remove the switch. SW16-1 SW16-2 INSTALLATION Installation is an exact reversed procedure of removal. ADJUSTMENT Adjust the switches so that they actuates when the plastic cover is pressed 3-5 mm. MAIL INSERTER MODEL 45 PAGE 4.10.1 SEP -98...

  • Page 28: Rep 4.11 Water Level Sensor (Sen17)

    Installation is an exact reversed procedure of removal. CAUTION: Make certain that the water level sensor not is in contact with the water tray. ADJUSTMENT Loosen the nuts on motor bracket to adjust the tension of the timing belt. MAIL INSERTER MODEL 45 PAGE 4.11.1 JAN -04...

  • Page 29: Rep 4.12 Envelope Position Encoder 1 (Sen18)

    7. Lift out the motor and disconnect the envelope position encoder connector. Remove the encoder bracket. Remove the encoder. INSTALLATION Installation is an exact reversed procedure of removal. ADJUSTMENT Loosen the nuts on motor bracket to adjust the tension of the timing belt. MAIL INSERTER MODEL 45 PAGE 4.12.1 SEP -98...

  • Page 30: Rep 4.13 Envelope Position Encoder 2 (Sen19)

    7. Remove the encoder bracket. 8. Remove the encoder. INSTALLATION Installation is an exact reversed procedure of removal. ADJUSTMENT Loosen the nuts on motor bracket to adjust the tension of the timing belt. MAIL INSERTER MODEL 45 PAGE 4.13.1 SEP -98...

  • Page 31: Rep 5.1 Envelope Flap Opener Motor (Mot2)

    Adjust the motor so the drive belt slightly skid or tend to skid on the drive pulley. If the drive belt is too tight the flap guide plate will bounce and cause jam. Loosen the nuts on motor bracket to adjust the tension of the drive belt. MAIL INSERTER MODEL 45 PAGE 5.1.1...

  • Page 32: Rep 5.2 Envelope Positioning Motor (Mot3)

    Installation is an exact reversed procedure of removal. Calibrate motor M3 according to SER 9.3. Check the condition of the timing belt before refitting. ADJUSTMENT Loosen the nuts on motor bracket to adjust the tension of the timing belt. MAIL INSERTER MODEL 45 PAGE 5.2.1 JAN -04...

  • Page 33: Rep 5.3 Env. Opener Motor (Mot4) And

    Calibrate motor M5 according to SER 9.3. Check the condition of the timing belt/s before refitting. ADJUSTMENT Loosen the hex screws on motor bracket to adjust the tension of the timing belt. MAIL INSERTER MODEL 45 PAGE 5.3.1 JAN -04...

  • Page 34: Rep 5.4 Envelope Flap Guide Motor (Mot7) & Flap Guide

    Note: For versions lower than 2.00 the space should be 1 mm. With the flap guide in down dead centre, make sure that the flap guide is straight and parallel to the wetting roller. Form the plate and repeat adjustment if necessary. MAIL INSERTER MODEL 45 PAGE 5.4.1...

  • Page 35: Rep 5.5 Envelope Sealing Motor (Mot8)

    Installation is an exact reversed procedure of removal. Calibrate motor M8 according to SER 9.3. Check the condition of the timing belt before refitting. ADJUSTMENT Loosen the nuts on motor bracket to adjust the tension of the timing belt. MAIL INSERTER MODEL 45 PAGE 5.5.1 JAN -04...

  • Page 36: Rep 5.6 Envelope Wetting Roller Motor (Mot9)

    Installation is an exact reversed procedure of removal. Check the condition of the timing belt before refitting. ADJUSTMENT Loosen the nuts on motor bracket to adjust the tension of the timing belt. 5.6.1 MAIL INSERTER MODEL 45 PAGE SEP -98...

  • Page 37: Rep 5.7 Envelope Feed Belt Motor (Mot10)

    5. Remove the four screws fastening the envelope feed belt motor (1) to the gearbox (3). 6. Remove the envelope feed belt motor. INSTALLATION Installation is an exact reversed procedure of removal. 5.7.1 MAIL INSERTER MODEL 45 PAGE SEP -98...

  • Page 38: Rep 5.8 Envelope Opener Tools, Adjustments

    Check that the distance between the upper part of the opener tool (6) and the side tongues (5) are 5-6mm in insert position. See left picture. 5-6mm Envelope opener tool in insert Envelope opener tool in home position position. MAIL INSERTER MODEL 45 PAGE 5.8.1 JUN -00...
  • Page 39 The adjustment can be done in two ways. Always start with a). a) Adjust the two black studs (4) until correct position is obtained. b) Slightly form the plate (1) until the oneway-grass is touching the envelope tools. MAIL INSERTER MODEL 45 PAGE 5.8.2...

  • Page 40: Rep 5.9 Guide Plate Adjustment, Sealing Section

    (3). Note: Use a scale or similar and place it against the vertical side of the guide plate to easier see if the guide plate is vertical or not. Small play MAIL INSERTER MODEL 45 PAGE 5.9.1 JUN -00...
  • Page 41 PAGE INTENTIONALLY BLANK...

  • Page 42: Rep 6.1 Insert Feed Belts

    6. Remove the cover plate (6) by removing the nuts (7). 7. Remove the insert feed belts. INSTALLATION Installation is an exact reversed procedure of removal. NOTE: Carry out adjustments before refitting the document feeding unit. 6.1.1 MAIL INSERTER MODEL 45 PAGE SEP -98...
  • Page 43 The parallelism of the fingers on the insert feed belts must not differ more than 0.5 mm, measured in total on both pairs. Adjust by loosening one of the pulleys (1) on the drive shaft. Calibrate motor M5 according to SER 9.3 when adjustment is completed. 6.1.2 MAIL INSERTER MODEL 45 PAGE SEP -98...

  • Page 44: Rep 6.2 Flap Opener Drive Belt

    Loosen the nuts (2) on the envelope flap opener motor (MOT2) bracket. Remove the drive belt (1). INSTALLATION Installation is an exact reversed procedure of removal. ADJUSTMENT Perform adjustment according to REP 5.1. MAIL INSERTER MODEL 45 PAGE 6.2.1 JAN -04...

  • Page 45: Rep 6.3 Envelope Feed Belts

    Gently bend the plastic gear racks (16) in order to facilitate the removal. INSTALLATION Installation is an exact reversed procedure of removal. ADJUSTMENT Adjust the tension of the belts by turning the chamfered allen screws (12) at the right side bearing brackets. MAIL INSERTER MODEL 45 PAGE 6.3.1 SEP -98...

  • Page 46: Rep 7.1 Control Panel

    2. Loosen the screw (1) on the back side of the control panel. 3. Push the control panel towards the rear side and lift it. 4. Remove the ground wire and the ribbon cable. INSTALLATION Installation is an exact reversed procedure of removal. MAIL INSERTER MODEL 45 PAGE 7.1.1 SEP -98...

  • Page 47: Rep 7.2 Processor

    NOTE: On the socket under the processor there is an arrow (3). Install the processor so that the arrow will be pointing towards the small indent (2) on the processor. CAUTION: After the processor has been installed, follow REP 7.3 to reset the EEPROM. MAIL INSERTER MODEL 45 PAGE 7.2.1...

  • Page 48: Rep 7.3 Eeprom

    Open and close the envelope feed table. The inverted sensor S12 is now back to standard operation. Calibrate motors M3, M5 and M8. Enter service mode according to SER 9.1, Calibrate the motor according to SER 9.3 MAIL INSERTER MODEL 45 PAGE 7.3.1 JAN -04...
  • Page 49 Switch off the main power switch and disconnect the power cord. Remove the control panel according to REP 7.1. Remove the EEPROM (IC2). DIP No. 2 Set display Contrast with this potentiometer. INSTALLATION Installation is an exact reversed procedure of removal. MAIL INSERTER MODEL 45 PAGE 7.3.2 JAN -04...
  • Page 50 Installation is an exact reversed procedure of removal. Note: The PCB comes without processor. Move the processor from the old PCB or install a new according to REP 7.2 and reset EEPROM according to REP 7.3. MAIL INSERTER MODEL 45 PAGE 7.4.1...

  • Page 51: Rep 7.5 Wetting Roller And Wetting Cloth

    Indication of cloth not beeing stretched enough is that it jumps slightly when rotating. It can be checked by starting the wetting roller M9 according to SER 9.3. MAIL INSERTER MODEL 45 PAGE 7.5.1...
  • Page 52 PAGE INTENTIONALLY BLANK...
  • Page 53 PAGE INTENTIONALLY BLANK...

  • Page 54: Ser 9.1 Entering The Service Mode

    SER 9.1 Entering the service mode T08090 To enter the service mode: • Press and hold the rightmost button pressed on the control panel. • Switch on the power. MAIL INSERTER MODEL 45 PAGE 9.1.1 SEP -98...

  • Page 55: Ser 9.2 Self Test Program

    SER 9.2 Self test program T08090 The self test program could be run in order to verify the status of the Model 45 if some problems are experienced. The self test program will perform a test of the EEPROM, sensors, motors and circuits as well as checking of different voltages.

  • Page 56: Ser 9.3 Check Motors

    EEPROM S P E E D = 2 . 0 0 M / S reset is performed. The Model 45 will automatically calibrate the speed. Press the stop button to store value.
  • Page 57 C H E C K M O T O R S the right signal when the Model 45 is empty and all the C H E C K S E N S O R S V O L T M E T E R sensors are in their home position.

  • Page 58: Ser 9.5 Voltmeter

    ASP is when the motor start slowing down and ESP is the absolute stop. To adjust ESP, choose “Env. stop. pos.” and press the “OK” button. Adjust with the up/down arrow buttons. If increasing value, envelope will travel longer. MAIL INSERTER MODEL 45 PAGE 9.5.1 JAN -04...

  • Page 59: Ser 9.7 Insert Position

    The counter shows the number sets runned. R U N N I N G D E A D C Y C L I N G 0 0 0 0 1 9 0 MAIL INSERTER MODEL 45 PAGE 9.7.1 JAN -04...

  • Page 60: Ser 9.9 Total Counter

    0 0 0 0 1 9 0 SER 9.10 Interface The purpose is to adapt the Model 45 to the type of interface to which it is installed. Choose “INTERFACE” A C T I V E S T O P P O S .

  • Page 61: Ser 9.11 Jog

    Positioning before sealing. Position 5 Sealing. Position 6 Envelope flap guide up. Press the start button once more to deliver the envelope to the recieving tray and to return to position 1. MAIL INSERTER MODEL 45 PAGE 9.11.1 JAN -04...

  • Page 62: Mai 10.1 Cleaning The Water Tray

    • Follow REP 3.3 step 1-7 to drain the • Unlock the water tray by pushing it to the left (1) and fold it downwards (2). • Clean the water tray. MAIL INSERTER MODEL 45 PAGE 10.1.1 JAN -04...
  • Page 63 Hold the guide plate in the correct position (1) while folding the water tray upwards (2) until it snaps into locked position. guide plate correct position water tray Note: See REP 5.9 for adjustment of guide plate. MAIL INSERTER MODEL 45 PAGE 10.1.2 JAN -04...

  • Page 64: Mai 10.2 Preventive Maintenance Service

    Note: All INSTRUCTIONS are referring to the Mailer Model 45 Service Manual. The REFERENCE column is referring to the Spare parts list of Model 45. Important: If any of the checkpoints or other parts show indication of wear at any point, replace the part.
  • Page 65 Page 1.17 Check Check damper. If worn, replace. Check Item 8 for wear of the plastic opener tongue, if worn replace. Check that there is a proper play between plate and frame. MAIL INSERTER MODEL 45 PAGE 10.2.2 JAN -04...
  • Page 66 500 000. Envelope infeed Use a rubber reactivator alcohol Page 1.15 Clean Replace wheels fluid to clean the wheels. Check Item 1 for wear, if worn replace. Replace every 500 000. MAIL INSERTER MODEL 45 PAGE 10.2.3 JAN -04...

  • Page 67: Fip 11.1 Fault Code Description

    Check for app. 36 volts DC between red Rectifier R1 or capacitor C1 defective. and black wire on out side of rectifier. If not app. 36 volts: Replace rectifier R1. If app. 36 volts: Replace capacitor C1. MAIL INSERTER MODEL 45 PAGE 11.1.1 JAN -04...
  • Page 68 2. If not app. 36 volts: See fault code 2. Fault code: Error message: REGULATED VOLTAGE HIGH Action Possible Cause Replace PCB according to REP 7.4. PCB defective. MAIL INSERTER MODEL 45 PAGE 11.1.2 JAN -04...
  • Page 69 If not lit: Replace LED. If lit: Replace photo transistor. Check continuity for wires between PCB Wires defective. and sensor. See wiring diagram. Replace PCB according to REP 7.4. PCB defective. MAIL INSERTER MODEL 45 PAGE 11.1.3 JAN -04...
  • Page 70 REP 4.9. Measure between P5-4 and P5-9. Connectors or wires defective. If contact: Repair wiring between J1 and J5. If no contact: Replace plug and jack according to REP 4.9. MAIL INSERTER MODEL 45 PAGE 11.1.4 JAN -04...
  • Page 71 If no contact: Check wiring for open circuit. Measure between P5-5 and P5-10. Wires defective. If contact: Repair wiring between J1 and J5. If no contact: Repair wiring in P5. See REP 4.1 for how to access. MAIL INSERTER MODEL 45 PAGE 11.1.5 FEB -04...
  • Page 72 De-ionized water should not be used in the De-ionized water in sealing system. Model 45. Drain the sealing system according to REP 3.3 and refill with regular tap water. Clean the water tray and sensor according Sensor not clean.
  • Page 73 FIP 11.1 Fault code description continues T08090 Fault code: 31, 33, 35, 37, 39, 41, 43, 45, 47 or 49 Error message: MOTOR M# OPEN CIRCUIT Action Possible Cause Reset EEPROM according to REP 7.3. EEPROM error Run motor M# according to SER 9.3. If Motor M# defective.
  • Page 74 Check sensor LED for red light. LED not lit: Replace LED. LED lit: Replace photo transistor. Check continuity for wires between PCB Wires defective. and sensor. See wiring diagram. Replace PCB according to REP 7.4. PCB defective. MAIL INSERTER MODEL 45 PAGE 11.1.8 JAN -04...
  • Page 75 If it stops: OK. If not stops: Tap on “Relay 1” and check if function is regained. If not: Replace “Relay 1” on PCB or Replace PCB according to REP 7.4. MAIL INSERTER MODEL 45 PAGE 11.1.9 JAN -04...

  • Page 76: Fip 11.2 Trouble Shooting

    FIP 11.2 Trouble shooting T08090 Sealing jam Problem: • Sealing Jam message. • Envelope exits Model 45 with flap open in sealing mode. • The inserts are properly inserted into the envelope. Possible Cause Action Component failure Run the Diagnostics according to SER 9.2.
  • Page 77 Adjust insert feed belt parallelism according to REP 6.1. Change Envelopes Overall speed of Model 45 too slow. Increase speed on collator, PL46 and PL49 if installed. If hand-feeding, enter service mode and increase speed under “jog”. Flap guide plate loose.
  • Page 78 See REP 5.8. Outfeed paper path not in position or Place paper path in position. If damaged damaged. replace. MAIL INSERTER MODEL 45 PAGE 11.2.3 JAN -04...
  • Page 79 Model 45. The inserts do not land properly on the Use mylar strips where applicable. document feed table. Move Model 45 relative the feeder if applicable. The side guides on the document table are For matched inserts to envelope (such as in the wrong position.
  • Page 80 Oversize envelope adjustment knobs Loosen the knob. Push the bracket upwards brackets positioned skewed. to make sure 45 degree angeled portion is in firm contact with the fixed one way grass. Feeder is not running in correct speed. Adjust feeder speed if applicable. Replace feeder motor where only option.
  • Page 81 • No reactions from the machine Possible Cause Action Fuse F2 blown Check/Replace Fuse F2. Located on the transformer, to the left (when facing the transformer). Component failure Run the Diagnostics according to SER 9.2. MAIL INSERTER MODEL 45 PAGE 11.2.6 FEB -04...

  • Page 82: Fip 11.3 Principle Of Operation

    After app. 270 pulses M3 starts slowing down to stop exactly at 350. 10. M3 envelope position rollers stops (after the 350 pulses). 11. S7 envelope position 4 is blocked (high). MODEL 45 IS NOW IN STANDBY MODE, AWAITING END OF SET SIGNAL FROM HOST MACHINE MAIL INSERTER MODEL 45 PAGE 11.3.1...
  • Page 83 FIP 11.3 Priciple of Operation continues T08090 MODEL 45 IS NOW IN STANDBY MODE, AWAITING END OF SET SIGNAL FROM HOST MACHINE 12. End of set signal from host machine. 13. M4 envelope opener starts. 14. M4 envelope opener stops in the left most position by signal from S4.

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