SI-30 Info.

ISSUE : 29/10/04 SI30 / M1000 / CARAT XS SERVICE MANUAL
REVISION : 2.2
SECTION : 01 PAGE 1
GENERAL MENU
Click
SECTION 1: MAINTENANCE page
1 INTRODUCTION ..................................................................................................2
1.1 PRECAUTION ............................................................................................................................. 2
1.2 TERMINOLOGY .......................................................................................................................... 3
1.3 GENERAL OVERVIEW............................................................................................................... 5
1.4 SENSORS/SWITCHES, MOTORS AND CLUTCHES.............................................................. 11
1.5 PCB INTERCONNECTION DIAGRAM..................................................................................... 13
1.6 PROTOCOL AND HARDWARE CONFIGURATION ............................................................... 16
2 SERVICE CALL CHECK LISTS.........................................................................17
2.1 START OF SERVICE CALL CHECK LIST .............................................................................. 17
2.2 END OF SERVICE CALL CHECK LIST ................................................................................... 17
2.3 PREVENTIVE MAINTENANCE ................................................................................................ 18
2.4 MAINTENANCE KITS DETAILS .............................................................................................. 19
3 SOFTWARE UPGRADE AND CPU BOARD REPLACEMENT .........................27
3.1 SOFTWARE UPGRADE ........................................................................................................... 27
3.2 CPU BOARD REPLACEMENT ................................................................................................ 27
4 DIAGNOSTICS TOOL ........................................................................................28
4.1 ERROR MESSAGE LIST.......................................................................................................... 28
4.2 FUNCTIONAL FAULTS ............................................................................................................ 30
4.3 FUNCTIONAL TESTS............................................................................................................... 31
5 DISASSEMBLING, RE-ASSEMBLING AND ADJUSTMENTS..........................38
5.1 TOOLS ...................................................................................................................................... 38
5.2 DISASSEMBLING..................................................................................................................... 38
5.3 RE-ASSEMBLING AND ADJUSTMENTS ............................................................................... 39
5.4 FEEDER C SEPARATION ADJUSTMENT .............................................................................. 40
5.5 DISASSEMBLING AND RE-ASSEMBLING SUMMARY......................................................... 42
6 THEORY OF OPERATION.................................................................................43
6.1 KEY CODES.............................................................................................................................. 43
6.2 USER MODE DIAGRAM........................................................................................................... 44
6.3 SETTING MODE DIAGRAM (ADVANCED USER MODE) ...................................................... 45
6.4 BASE SERVICE MODE ............................................................................................................ 46
6.5 SEQUENCES OF SOFTWARE FUNCTIONS .......................................................................... 47
7 EUROPE SPECIFICATIONS..............................................................................48
8 USA SPECIFICATIONS .....................................................................................50
9 RECOMMENDED SPARE PARTS LIST............................................................52
FOR0130 / A DISCS10000_A
REVISION : 2.2
SECTION : 01 PAGE 2
MENU
1 INTRODUCTION
1.1 PRECAUTION
Actuators : never grease or lubricate plastic parts in movement . Only use compressed air for cleaning and
maintenance.
Never grease ball bearings.
It is strongly advised to use only the recommended grease (grease of synthesis) as certain types of grease may
damage the mechanisms of the machine.
Empty the water tank before transporting the machine.
MAINTENANCE PRODUCTS
Grease: MOLYCOTE PLASTISLIP PG75 (plastic parts)

ESSO MULTIPURPOSE 4746 (bearing output roller)
REVISION : 2.2
SECTION : 01 PAGE 3
MENU
1.2 TERMINOLOGY
A SELECTION See description in Section 1, Chapter 1.4.1 "Sensors"

CLUTCH
A, feeder A Front manual and automatic feeder for documents
A-EMPTY See description in Section 1, Chapter 1.4.1 "Sensors"
B SELECTION See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
CLUTCH
B, feeder B Rear automatic feeder for documents
B-EMPTY See description in Section 1, Chapter 1.4.1 "Sensors"
BOTTOM FOLDER See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
MOTOR
C SELECTION See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
CLUTCH
C TRANSPORT See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
CLUTCH
C, feeder C Automatic feeder for inserts or BRE
CAM MOTOR See description in Section 1, Chapter 1.4.1 "Sensors"
CAM-ZERO See description in Section 1, Chapter 1.4.1 "Sensors"
C-CLOSED See description in Section 1, Chapter 1.4.1 "Sensors"
C-EMPTY See description in Section 1, Chapter 1.4.1 "Sensors"
DD-A See description in Section 1, Chapter 1.4.1 "Sensors"
DD-B See description in Section 1, Chapter 1.4.1 "Sensors"
DD-C See description in Section 1, Chapter 1.4.1 "Sensors"
DD-KEY See description in Section 1, Chapter 1.4.1 "Sensors"
DOC-LOADED See description in Section 1, Chapter 1.4.1 "Sensors"
DOCUMENT FEEDER See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
CLUTCH
END-SEPARATION-A See description in Section 1, Chapter 1.4.1 "Sensors"
END-SEPARATION-B See description in Section 1, Chapter 1.4.1 "Sensors"
END-SEPARATION-C See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
ENV TRANSPORT See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
MOTOR
ENV-EXIT See description in Section 1, Chapter 1.4.1 "Sensors"
ENV-REFERENCE See description in Section 1, Chapter 1.4.1 "Sensors"
Flash Memory including the software
Hopper Envelope feeder
HOPPER MOTOR See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
INSERT-SIGNAL See description in Section 1, Chapter 1.4.1 "Sensors"
INSERT-STOP See description in Section 1, Chapter 1.4.1 "Sensors"
LETTER-OUTPUT See description in Section 1, Chapter 1.4.1 "Sensors"
MACHINE-OPEN See description in Section 1, Chapter 1.4.1 "Sensors"
MAIN MOTOR See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
MANUAL FEEDING See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
MOTOR
MMI Man Machine Interface
MULTI Multimeter in ohmmeter position.
SINGLE FOLD MOTOR See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
REVISION : 2.2
SECTION : 01 PAGE 4
MENU
TOP FOLDER MOTOR See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
Type E sensor Electrodes
Type F sensor Flag sensor
Type H sensor Hall effect sensor
Type PP motor stepper motor
Type R sensor Reed bulb (activation of a mechanical switch under a magnet effect)
Type S switch Mechanical Switch
Icons:
Fix: Job memorized Job secured (locked)

Blinking: Job modified

Type of folds :
Single fold C fold or letter fold Double parallel fold
REVISION : 2.2
SECTION : 01 PAGE 5
MENU
1.3 GENERAL OVERVIEW
1.3.1 FEEDER A-B SENSORS AND SWITCH VIEW
DD-A DD-B END SEPARATION - B END-SEPARATION-A
B-EMPTY
DD-KEY A-EMPTY / AUTOSTART B-EMPTY
REVISION : 2.2
SECTION : 01 PAGE 6
MENU
1.3.2 BASE SENSORS AND SWITCH VIEW
C.EMPTY
LETTER.OUTPUT
ENV.EXIT
MACHINE
OPEN
C.CLOSED
END AND
SEPARATION C
DD.BAC.C
REF.ENV
INSERT.STOP
FOLDING PLATE
2
DOC.LOADED
ZERO.CAME
REVISION : 2.2
SECTION : 01 PAGE 7
MENU
1.3.3 BASE SENSORS AND SWITCH VIEW
MACHINE-OPEN
1.3.4
LETTER-OUTPUT
DD-C
ENV-EXIT
ENV-REFERENCE
END-SEPARATION-C
INSERT-STOP
C-EMPTY
C-CLOSED
CAM-ZERO
DOC-LOADED INSERT-SIGNAL
REVISION : 2.2
SECTION : 01 PAGE 8
MENU
1.3.5 CLUTCHES VIEW
B SELECTION
CLUTCH MANUAL
FEEDING
MOTOR
A SELECTION
CLUTCH
C SELECTION C TRANSPORT CLUTCH DOCUMENT FEEDER

CLUTCH CLUTCH
REVISION : 2.2
SECTION : 01 PAGE 9
MENU
1.3.6 MOTORS VIEW
HOPPER
MOTOR MAIN MOTOR
ENV
TRANSPORT
MOTOR
SINGLE FOLD
MOTOR TOP FOLDER
(EUR only) MOTOR
BOTTOM
FOLDER
MOTOR
CAM MOTOR
REVISION : 2.2
SECTION : 01 PAGE 10
MENU
1.3.7 PAPER PATH VIEW
DOCUMENT PATH
ENVELOPE PATH
REVISION : 2.2
MENU
1.4 SENSORS/SWITCHES, MOTORS AND CLUTCHES
1.4.1 SENSORS
MACHINE SENSORS (PART 1)

SERVICE TEST COMPONENT NAME FUNCTION
Bin C path closed C-CLOSED Checks if feeder C path is closed
Exit env. feeder ENV-EXIT Checks if the envelope has left the envelope hopper
Machine open MACHINE-OPEN Checks if the machine is open
End separation C END-SEPARATION-C C SEPARATION CLUTCH drive
Document in feeder C C-EMPTY No inserts in the feeder C
Document loaded DOC-LOADED inserting check
Stop insert INSERT-STOP Insert (or BRE) stop position
MACHINE SENSORS (PART 2)
Insert signal INSERT-SIGNAL Synchronization document / Insert (or BRE)
Envelope Exit LETTER-OUTPUT Letter output check
Envelope Ref. ENV-REFERENCE Reference for the envelope inserting position
Cam zero CAM-ZERO Cam home position
FEEDER A-B SENSORS
Document in feeder A A-EMPTY / AUTOSTART No document in feeder A / AUTOISTART
Document in feeder B B-EMPTY No document in feeder B
End separation A END-SEPARATION-A A SEPARATION CLUTCH drive
End separation B END-SEPARATION-B B SEPARATION CLUTCH drive
Double detection key DD-KEY Enable or disable DD-A and DD-B
DOUBLE DETECTION (Thickness detection)
Entry doc A sensor DD-A Voltage delivered by the feeder A duplicate detector
Entry doc B sensor DD-B Voltage delivered by the feeder B duplicate detector
Entry doc C sensor DD-C Voltage delivered by the feeder C duplicate detector
REVISION : 2.2
MENU
1.4.2 MOTORS AND CLUTCHES
FEEDERS CLUTCHES
Not available A SELECTION CLUTCH Activate feeder A selection rollers
Not available B SELECTION CLUTCH Activate feeder B selection rollers
Not available C SELECTION CLUTCH Activate feeder C selection rollers
MACHINE CLUTCHES
Not available C TRANSPORT CLUTCH Activate the transport C rollers.
- Transfer mechanical power to document feeders
Not available DOCUMENT FEEDER CLUTCH
- Activate document transportation until folding rollers.
MOTORS
Not available TOP FOLDER MOTOR Drives Top folder adjustment
Not available BOTTOM FOLDER MOTOR Drives Bottom folder adjustment
- Drives the folding rollers.
Not available MAIN MOTOR - Documents feeding.
- Insert/BRE feeding
Not available CAM MOTOR Drives the cam (inserting area)
Drives envelope from the hopper exit until the exit of
Not available ENV TRANSPORT MOTOR
the machine
Not available HOPPER MOTOR Drives the envelope until the hopper exit.
Not available SINGLE FOLD MOTOR Drives the pocket A closing bar (Europe only)
Not available MANUAL FEEDING MOTOR Opens the feeder A path in order to perform daily mail
REVISION : 2.2
MENU
1.5 PCB INTERCONNECTION DIAGRAM
1.5.1 MAIN PCB (PART 1)
1.5.2
REVISION : 2.2
MENU
1.5.3 MAIN PCB (PART 2)
1.5.4
REVISION : 2.2
MENU
1.5.5 FEEDER PCB
1.5.6
REVISION : 2.2
MENU
1.6 PROTOCOL AND HARDWARE CONFIGURATION
LEFT INTENTIONALLY BLANK
REVISION : 2.2
MENU
2 SERVICE CALL CHECK LISTS
2.1 START OF SERVICE CALL CHECK LIST
Check the user has been trained on the machine.

Check the application corresponds with the job in process.
Check the properties of the job correspond to the machine specifications.
What is the total number of cycles?
What is the rate of clogging up of the machine (does the user apply the recommended cleaning procedures?).
2.2 END OF SERVICE CALL CHECK LIST
Clean the transportation and folding rollers.

Inform the user about the origin of the fault and show how to avoid it in the future.
Test the job in process (process at least thirty documents).
Rinse the wetting brushes under warm water.
Check the moistening quality.
Check the water level in the tank.
REVISION : 2.2
MENU
2.3 PREVENTIVE MAINTENANCE
SPARE / KIT PN REGULAR "HIGH VOLUME" CUSTOMER

CUSTOMER
30000 or 60000 90000 120000 150000 180000
once a year
Rollers cleaning - X X X X X End of
Life
Moistening brushes replacement 4124581N X X X X X End of
Life
Inserting fingers and rollers 4124587U (EUR) X End of
replacement 4124831Y (US) Life
Feeder C maintenance 4124590X X End of
Life
Feeder E maintenance 4124591Y X X End of
Life
C path maintenance 4124592Z X X End of
Life
Doc. Transport. Maintenance 4124594B X End of
Life
Exit rollers maintenance 4124603L X X End of
Life
Feeder AB replacement (swap) 4120482T X End of
Life
Regular customer: 1000 cycles per month / 5 years
"Hi Volume" customer: up to 3000 cycles per month / 5 years
REVISION : 2.2
MENU
2.4 MAINTENANCE KITS DETAILS
Kit description Series 1 Part Quantity French description English description

compatibil
ity
number
Envelope stop YES 11PIA0001 6 Paliers Bearings
4124580M
YES 11PIA0020 2 Support arrt enveloppe Enveloppe stop bracket
YES 11PIC0085 1 Dflecteur volet enveloppe Envelope flap deflector
YES 11PIC0089 1 Languette gauche ouverture Tongue - left
enveloppe
YES 11PIC0156 1 Languette droite ouverture enveloppe Tongue - right
YES 11PIC0220 2 Languette arrt enveloppe Tongue - envelope stop
YES 21PIA0001 1 Contre rouleau arrt enveloppe Pressure roller - envelope stop
YES 21PIA0034 1 Rouleau arrt enveloppe Drive roller - Envelope stop
YES 21PIA0035 1 Ejection enveloppe Ejection roller - Envelope stop
NO 4122298K 1 Capteur arrt enveloppe Sensor - Envelope stop
Brush YES 21PIA0027 3 Brosses de mouillage Moistening brush
4124581N
Cam YES 11PIA0122 1 disque zro came Cam disc
4124582P
YES 11PIC0127 1 Came sortie droite Right exit cam
YES 11PIC0128 1 Came sortie gauche Left exit cam
YES 11PIC0213 1 Came intrieur gauche left cam
YES 11PIC0214 1 Came intrieur droite right cam
Sensors NO 4121929A 1 Ens DD-C DD-C assembly
4124583Q
NO 4122298K 5 Zero came - chargement - Arrt env - Sensors
sortie env
NO 4122982X 5 Ens capteur chemin encart Insert path sensor assembly
NO 4123041J 1 Ens capteur sortie env LETTER-OUTPUT sensor assembly
NO 4123044M 1 Ens capteur ref selection env. ENV-REFERENCE sensor assembly
REVISION : 2.2
KITS DETAILS (FOLLOW UP) MENU

compatibil
ity
number
Belts YES 12NCA000 1 Courroie Chemin inf C Insert lower path belt
4124584R 4
YES 12PIA0003 1 Courroie moteur env Envelope motor belt
YES 12PIA0006 1 Courroie de chargement Inserting belt
YES 12PIA0007 1 Cde came Cam belt
YES 12PIB0002 1 poche A Pocket A belt
YES 12PID0001 1 Courroie cde bac C Bin C belt
Clutches YES 14PIC0002 3 1 bac C, 1 transport C, 1 pliage Clutch
4124585S
Pocket A closing YES 11BFA240 1 Pignon intermdiaire fermeture poche Gear (intermediate) - closing bar
(Europe use only) 2
4124586T
YES 11PIC0075 2 Palier barette de fermeture poche Bearing - pocket closing bar
YES 11PIC0091 1 Pignon cde levier gauche Gear - left lever drive
YES 11PIC0092 1 Levier pivot droit (fermeture de Right lever
poche)
YES 11PID0093 2 Levier de cde fermeture poche Pocket closing drive lever
YES 11PID0106 1 Barette fermeture poche Closing bar
YES 21PID0032 1 Support gauche barrette de fermeture Left bracket
poche
YES 21PID0033 1 Support droit barrette de fermeture Right bracket
poche
NO 4121971U 1 Moteur pas a pas Stepper motor
Inserting (Europe) YES 11PIA0053 1 poulie rouleau chargement Pulley - inserting roller
4124587U
YES 4123028V 1 Ensemble doigts d'insertion Europe Insert fingers assembly (Europe)
quip
YES 11PIA0326 1 poulie rouleau chargement Pulley - inserting roller
YES 12PIA0006 1 Courroie de chargement Belt - inserting
YES 21PIA0053 1 Poulie cde courroie chargement Pulley - inserting belt
YES 21PIC0026 1 Rouleau d'insertion quip Inserting roller assembly
REVISION : 2.2

compatibil
ity
number
Inserting (US) YES 11PIA0053 1 poulie rouleau chargement Pulley - inserting roller
4124831Y
YES 4123029W 1 Ensemble doigts d'insertion US Insert fingers assembly (US)
quip
YES 11PIA0326 1 poulie rouleau chargement Pulley - inserting roller
YES 12PIA0006 1 Courroie de chargement Belt - inserting
YES 21PIC0026 1 Rouleau d'insertion quip Inserting roller assembly
Tongues YES 11PIA0093 4 patins amortissants pieds Shock absorber - feet
4124588V
YES 11PIC0089 1 Languette gauche ouverture Left tongue - envelope pre-opening
enveloppe
YES 11PIC0156 1 Languette droite ouverture enveloppe Right tongue - envelope pre-opening
YES 11PIC0220 2 Languette arrt enveloppe Tongue - envelope stop
YES 11PIC0223 1 languette bac E Tongue - bin E
YES 11PID0125 1 Languette entre chemin C Tongue - path C entrance
YES 11PID0126 2 Cache fil Tongue - Cable protection
Exit lever deflector YES 21PIA0117 1 Levier pr-mouillage droit Lever - pre-moistening (right)
4124589W
YES 21PIA0118 1 Levier pr-mouillage gauche Lever - pre-moistening (left)
Feeder C YES 11PIA0001 4 Palier Bearing
maintenance
4124590X
YES 11PID0139 2 Rouleau de slection Selection roller - feeder C
YES 21PIC0086 2 Ensemble filire Europe Separation assembly - Feeder C
Europe
YES 4122975Q 2 Ensemble filire US Separation assembly - Feeder C US
REVISION : 2.2

compatibil
ity
number
Feeder E YES 11PIA0386 2 Bute filire Separation assembly stop - Feeder E
maintenance
4124591Y
YES 11PIC0167 2 Revtement pour patin slection bac Separation pad covering - Feeder E
E
YES 11PIC0187 2 Patins de slection bac E Separation pad - Feeder E
YES 12PIA0002 1 Brosse prselection bac E Separation brush - Feeder E
YES 21PIA0017 1 Rouleau plein transport env Transportation roller (full) - Feeder E
YES 21PIA0081 2 Galets libres bac E Roller (free) - Feeder E
YES 21PIA0143 1 Contre rouleau transport doc Pressure roller
YES 21PIA0156 1 Ensemble rouleau 5 gommes bac E Roller (5 rubbers) - Feeder E
YES 21PIA0157 1 Ensemble rouleau 5 gommes mixtes Roller (5 mixed rubbers) - Feeder E
bac E
YES 21PIA0158 1 Ensemble rouleau 3 gommes bac E Roller (3 rubbers) - Feeder E
Inserts path YES 11PIA0001 12 Palier Bearing
maintenance
4124592Z
YES 11PID0013 2 Rouleau Chemin inf - axe court Lower roller (short) - Path C
YES 21PID0001 1 Rouleau Chemin inf - axe long Lower roller (long) - Path C
YES 21PID0003 3 Chemin sup Upper path - Path C
Folding maintenance YES 11PIA0001 12 Palier Bearing
4124593A
YES 11PID0154 1 Rouleau pliage N2 Folding roller (#2)
YES 11PID0156 1 Rouleau pliage N3 Folding roller (#3)
YES 11PIDO15 1 Rouleau pliage N4 Folding roller (#4)
5
Doc. Transport. YES 11PID0052 1 Rouleau arrire entre doc Entry roller (rear) - Document path
Maintenance
4124594B
YES 21PIA0143 1 Contre rouleau transport env Pressure roller
YES 11PIA0001 6 Palier Bearing
YES 21PIC0018 1 Rouleau avant entre doc Entry Roller (front) - Document path
YES 21PID0011 1 rouleau inf transport doc Lower roller - Document path
REVISION : 2.2

compatibil
ity
number
Feeder C gears YES 11BFA328 1 Pignon bac C Gear - Feeder C
4124595C 2
YES 11PIA0004 1 Pignon bac C Gear - Feeder C
YES 11PIA104 1 Pignon intermdiaire cde bac C Intermediate gear - Feeder C drive
YES 11PID0044 1 Pignon bac C Gear - Feeder C
YES 11PID0068 1 Pignon embrayage transport C Gear - Feeder C transport clutch
YES 11PID0088 1 Chemin C Gear - Feeder C (path)
YES 11PID0113 2 poulie chemin C Pulley - Feeder C
YES 4122039Q 2 Pignon crmaillre Rack gear - Feeder C
YES 4122040R 1 Pignon bac C Gear - Feeder C
YES 4122098B 1 Pignon bac C Gear - Feeder C
Feeder E gears YES 11PIA0025 1 Pignon intermdiaire Intermediate gear - Feeder E
4124596D
YES 11PIA0104 1 Pignon moteur bac E Motor gear - Feeder E
YES 11PIA0141 1 mont en pignon double Double gear - Feeder E
YES 11PIC0125 1 mont en pignon double Double gear - Feeder E
YES 21PIA0052 3 Pignon intermdiaire Intermediate gear - Feeder E
Inserting gears YES 11PIA0053 1 poulie rouleau chargement Pulley - Inserting roller
4124598F
YES 11PIA0326 1 poulie rouleau chargement Pulley - Inserting roller
YES 11PIB0007 1 Commande de came Cam drive - Inserting
YES 11PIB0038 1 pignon cde came Cam drive gear - Inserting
YES 11PIC0213 1 Pignon cde came Cam drive gear - Inserting
REVISION : 2.2

compatibil
ity
number
Doc. Transport. Gears YES 11PIA0082 2 Pignon rouleaux pliage N3 et 4 Gear - Folding rollers # 3 & 4
4124599G
YES 11PIA0082 1 Pignon rouleau pliage N1 Gear - Folding roller # 1
YES 11PIA0104 1 Pignon intermdiaire transport doc Intermetiate gear - Document path
YES 11PIC0139 1 Pignon rouleau arrire entre doc Gear (rear entry roller) - Document
path
YES 11PIC0140 1 Pignon rouleau avant entre doc Gear (front entry roller) - Document
path
YES 11PID0041 1 pignon embrayage entre doc Gear (entry doc clutch) - Document
path
YES 11PID0042 1 Pignon intermdiaire Intermetiate gear - Document path
YES 11PID0146 1 Pignon moteur transport doc Motor gear - Document path
YES 4122220D 1 Pignon rouleau pliage N2 Gear - Folding roller # 2
Env. transport. Gears YES 11PIA0025 1 Pignon rouleau arrt enveloppe Gear - Envelope stop roller
4124600H
YES 11PIA0026 1 Poulie rouleau jection enveloppe Pulley - Exit roller
YES 11PIA0027 1 Pignon rouleau ejection enveloppe Gear - Exit roller
YES 11PIB0043 1 Poulie cde rouleau de sortie Pulley - Exit roller drive
YES 11PIC0074 1 Pignon moteur transport enveloppe Motor gear - Envelope motor
YES 21PIA0059 1 Pignon/poulie chemin enveloppe Gear / pulley - Envelope path
YES 21PIC0001 1 Pignon/poulie transport enveloppe Gear / pulley - Envelope
transportation
YES 21PIC0051 1 Pignon chemin enveloppe (tarington Gear (Tarington clutch) - Envelope
clutch) path
REVISION : 2.2

compatibil
ity
number
Springs YES 11PIA0231 4 Ressort Chemin sup C (2eme et Spring - Upper path (2nd and 3rd) -
4124602K 3eme) Path C
YES 11PIA0456 2 Ressort Chemin sup C (1er ) Spring - Upper path (1st) - Path C
YES 11PIA0132 1 Ressort droit chemin C Spring - path C (right)
YES 11PIA0198 1 Ressort verrouillage margeurs bac E Spring - Feeder E side guides locking
YES 11PIA0223 2 Ressort bac C Spring - bin C
YES 11PIA0223 2 Ressort deflecteur mouillage Spring - Moistening deflector
YES 11PIA0225 2 Ressort levier cde mouillage Spring - moistening drive lever
YES 11PIA0229 2 Ressort rappel verrou machine Spring - machine locking
YES 11PIA0231 2 Ressort contre rouleau arrt Spring - Envelope stop pressure
enveloppe roller
YES 11PIA0231 2 Ressort contre rouleau transport doc Spring - Document transportation
pressure roller
YES 11PIA0232 4 Ressort rouleau pliage Spring - folding roller
YES 11PIA0257 1 Ressort courroie transport env. Spring - Envelope transportation belt
YES 11PIA0258 1 Ressort rappel ens arrt env Spring - Envelope stop assembly
YES 11PIA0307 1 Ressort tendeur courroie came Spring - belt cam
YES 11PIA0325 1 ressort tendeur courroie chargement Spring - inserting belt
YES 11PIA0456 2 Ressort contre rouleau transport env Spring - Envelope transportation
pressure roller
YES 11PIC0028 1 Ressort droit rouleau avant entre Spring (right) - front entry doc
doc
YES 11PIC0065 1 Ressort gauche rouleau avant entre Spring (left) - front entry doc
doc
YES 11PIC0138 1 Ressort deflecteur env. Spring - envelope deflector
YES 11PIC0192 2 Ressort prselection enveloppe Spring - envelope pre-separation
YES 11PIC0247 1 Ressort dflecteur sortie Spring - exit deflector
YES 11PID0021 2 bac C Spring - bin C
YES 11PID0054 1 Ressort droit barette entre doc Spring (right) - document entry bar
YES 11PID0055 1 Ressort gauche barette entre doc Spring (left) - document entry bar
YES 11PID0128 1 Chemin inf C Spring - lower path C
REVISION : 2.2

compatibil
ity
number
Exit rollers YES 11PIA0001 3 Palier Bearing
maintenance
4124603L
YES 21PIA0024 1 Rouleau de sortie inf Lower exit roller
YES 21PIA0055 1 Palier gauche rouleau de sortie sup Bearing (left) - upper exit roller
YES 4122861W 1 Rouleau de sortie sup Upper exit roller
Cable NO 4121904Z 1 cble base/alimenteur Cable - base/Feeder AB cnx
4124604M
NO 4121901W 1 Cble capteur bac C Cable - feeder C sensor
NO 4121898T 1 Cble capteur ouverture machine, Cable - machine opening, envelope
sortie enveloppe, ref env et selection exit, envelope reference and
env envelope separation sensors
NO 4121900V 1 cble capteur zero came et doc Cable - Zero cam and document
charg loaded sensors
NO 4121887G 1 Cable DD-C Cable - DD-C
NO 4122782P 1 cable document charg Cable - Document loaded sensor
NO 4121902X 1 cble embrayages bac C, Pliage et Cable - Feeder C, folding and
transport doc document transportation clutches
NO 4121916M 1 cable encart precharg Cable - insert preloaded sensor
NO 4121906B 1 cble moteur transport doc Cable - document transportation
motor
Feeder AB knobs YES 4105509W 2 Bouton de dvrouillage bacs AB Bin A&B unlocking knob
4124846P
YES 4105508V 2 Levier de dvrouillage guides bacs Feeder A&B side guides locking lever
AB
YES 4122955U 1 Capot cellule autostart quip Feeder AB Front cover equiped
REVISION : 2.2
MENU
3 SOFTWARE UPGRADE AND CPU BOARD REPLACEMENT

3.1 SOFTWARE UPGRADE
Note: the use of an anti-static bracelet is recommended for the handling of PCBs
1 Switch off and unplug the machine

2 Remove the top cover
3 Disconnect the top connectors on the MAIN PCB
4 Unscrew ( see section 1 chapter 5.2.2) and pivot the MAIN PCB
5 Replace the flash
6 Fit the MAIN PCB back and reconnect the cables
7 Put the top cover back
8 Plug and switch on the machine
Flash Memory
3.2 CPU BOARD REPLACEMENT
When the LOGIC PCB is replaced, all the data stored into the RAM are lost. The following settings have then to be
done:
Perform a RAM Reset

Set the machine serial number (Service Mode)
Set the total counter (Service Mode)
Set the Authorisation code
Customize the language (Advanced menu \ language)
Customize the envelopes format (Advanced menu \ set format)
Check the envelope inserting position for kind of envelope (Advanced menu)
Check the envelope moistening position (Advanced menu).
Set the jobs according to the applications (User menu).
Adjust the offset between documents of feeders A and B for each job using these combinations of feeders
(Advanced menu).
REVISION : 2.2
MENU
4 DIAGNOSTICS TOOL
4.1 ERROR MESSAGE LIST
Message displayed Likely Cause Remedy

CHECK THE No envelopes in the hopper. Reinsert envelopes.
ENVELOPE TRAY Envelope miss-feeding Adjust the side .guides
Envelope out of specification Check the specifications
Envelope path jammed Check the envelope path
CHECK THE DOCUMENT PATH The document did not exit from Check the setting of the feeder AB
the feeder clutches
Document out of specification Check the Specifications
Document path jammed (piece of Check the feeder and the
paper) document path
CHECK THE CONNECTION OF AB feeder connector Check the connections on both
THE PAPER TRAYS Disconnected. sides (feeder and main board)
CLOSE THE MACHINE Sensor "MACHINE-CLOSED" Check the sensor in the service
faulty or badly located mode and eventually adjust its
positioning.
DETECTION OF DUPLICATE Faulty "DD-x" sensor Check the faulty sensor in the
DOCUMENT IN TRAYS A-B service mode
DETECTION OF DUPLICATE Faulty "DD-x" sensor Check the faulty sensor in the
DOCUMENT IN TRAY C service mode
SWITCH THE MACHINE OFF AB feeder connector Check the connections on both
AND THEN ON AGAIN Disconnected. sides (feeder and main board)
Feeder AB PCB faulty Request a feeder swap.
OPEN THE MACHINE AND The machine was unable to run Check all the paper path and
CLOSE IT AGAIN through its normal cycle. perform a power cycle (OFF/ON)
KEYBOARD FAULT When powered up one or more Check the keyboard in the service
keys on the keyboard are mode
depressed.
CHECK THE Envelope jammed in Open the machine
ENVELOPE PATH The machine. and check the
Envelope path.
REVISION : 2.2
MENU
Message displayed Likely Cause Remedy

REMOVE THE DOCUMENTS Document Jam Clear the paper path in the feeder.
FROM THE ENTRY OF Check the setting of the feeder AB
TRAYS A + B Clutch badly set clutches
NO DOCUMENT IN THE Sensors faulty Check the sensors in the service

TRAY(S) mode.
CHECK THAT DOCUMENTS Sensors faulty or feeder AB Check the feeders sensors in the
ARE MOVING CORRECTLY clutches badly set service mode.
OUT OF TRAYS A,B or C Check the setting of the feeder AB
clutches
REMOVE DOCUMENTS The AUTOSTART sensor is faulty Check the sensor in the service
FROM TRAY A mode.
DUPLICATE DETECTION, Faulty "DD-x" sensor Check the faulty sensor in the
CHECK CONTENTS OF service mode
ENVELOPE
CHECK PAPER PATH OF Rollers clogged up. Clean the rollers
TRAY C Path C sensor faulty Check the sensor in the service
mode
CLOSE TRAY C Sensor faulty Check the sensor in the service
mode.
OPEN THEN CLOSE THE The machine was unable to run Check all the paper path and
MACHINE through its normal cycle. perform a power cycle (OFF/ON)
REVISION : 2.2
MENU
4.2 FUNCTIONAL FAULTS
SYMPTOMS Likely Cause Remedy

The machine pre-load feed the Bad setting of the clutches Check the setting of the feeder AB
documents from AB to the pre- clutches
loaded position then stop
After 3000 cycles, the machine get The authorization code was not Set the authorization code
blocked entered
Envelope not/bad closed Inadequate moistening Set the moistening position
Job mis-setting Check that the moistening is set in the
job selected
Bad fold lengths Check that the fold length / envelope
high are consistent
Bad inserting of the document Check the envelope stop position.
Clean the inserting rollers.
Set of document to be inserted too Try with a thinner set.
thick
Bad/no moistening Job miss-setting Check that the moistening is set in the
job selected
Exit roller wet Clean the exit roller
Envelope flap out of specification Check the envelope flap shape and
high in the specification
Offset between documents from Bad setting of the clutches Check the setting of the feeder AB
feeders A and B clutches
Document set ejected below the The envelope height doesn't match Check the job and the envelope
envelope with the job setting
Document set ejected after the Envelope not placed properly in the Check the envelope orientation in the
envelope feeder E feeder E
Sensor "REF-ENVELOPE" faulty Check sensor in the service mode
Paper jams Inserting rollers clogged up Clean the inserting rollers
Bad envelope inserting position Adjust the envelope inserting position.
REVISION : 2.2
MENU
4.3 FUNCTIONAL TESTS

4.3.1 ENVELOPE STOP POSITION
- Remove the upper cover.

- Check for presence of envelopes in the stacker.
- Actuate the AUTOSTART detector with a piece of cardboard stiff enough and hold it firmly in
order to not be gripped between the drive rollers.
- Start a manual cycle (holding the piece of cardboard).
- Wait for the machine to stop, open it and with a fine pencil, mark the envelope along the edge of
the upper deflector (21PIC0028) while pushing up the top inserting plate, and measure dimensions
A. The A nominal value must be :
- If the envelope height is 105 mm (4,13 in.) A = 6mm 3mm (0,23 in. 0,12 in.)
- If the envelope height is 152 mm (6 in.) A = 10mm 3mm (0,39 in. 0,12 in.)
- For the other envelopes A = 8mm 3mm. (0,31 in. 0,12 in.)
TOP INSERTING PLATE UPPER DEFLECTOR EDGE
REVISION : 2.2
MENU
4.3.2 FEEDER AB CLUTCHES SETTING
PURPOSE: To ensure the correct document pre-loading position and to ensure as well the proper
synchronisation between feeders A and B:
- A too low stopping position (clutch delay too long) causes deformation of thin and medium-
thickness documents by the stop and consequently misalignment from both bins.
- A Too high stopping position (clutch delay too short) includes risks of gripping defaults of thick
documents by the base and of misalignment with a second document.
ADJUSTMENT PROCEDURE:
- To control the stop position for the feeder A-B, it is necessary to select a job which uses the envelope
feeder as well as feeder A (or B).
- Load feeder A with only one document, but without any envelope in the feeder E.
- Start the job (push the START key).
- Rotate the feeder A-B, without disconnect it, in order to look at the document stop position.
- If the position isnt correct (see the picture below), it is necessary to apply the A & B CLUTCHES
SETTING procedure to adjust the timing value.
- Perform again this adjustment until the stop position is correct, then apply the same procedure for the
feeder B
INTERVALLE OF ALLOWED
STOP POSITION
REVISION : 2.2
- A & B CLUTCHES SETTING PROCEDURE:
- From the user menu, press ESC and keep it pressed while pressing the key UP , the
following screen will appear:
- Use the arrow key to select the line job number,
and select "job from1-9" with the key UP and valid with the key MEM .
- Select clutch A, set the value and valid with the key MEM .
- Use the same process for clutch B.
Note: the value reference is written underneath the feeder A-B
Reference
referencevalue
value
Exit this screen using the key ESC to return to user mode.
REVISION : 2.2
MENU
4.3.3 CAM POSITION AND CAM BELT TENSION
PURPOSE: To synchronise the position of the cams to ensure the correct tension of the cam belt.
- Ensure that the position of the RH cams is symmetrical to that of the LH cam
- Undo securing screw (1) which adjusts the cam belt.
- Introduce two 3 mm-diameter rods (0,12 in.) through the left rear and left front cams and the machine
bottom side plate. If necessary, move one of the cams in relation to the toothed belt.
- Tighten the belt adjustment fixing screw.
NOTE:
- Incorrect synchronisation of the cams causes machine operating fault (sealing and ejection faults)
- Incorrect belt tension gives rise to abnormal operating noise and may cause the cams to become out of
synchronisation and machine to stop.
REVISION : 2.2
MENU
4.3.4 INSERTER BELT TENSION
PURPOSE: To ensure that the belt tension is correct.
- The machine must be off and open with the covers removed.
- Undo screw (1) by one or two turns to release lever (2).
- Replace document support plate (3), if it has been removed.
- Place cam (4) in the position shown in the figure opposite.
- Rotate inserting roller (5) a few turns by its rubber rollers in the direction of operation in order to tension
the belt correctly.
- Tighten screw (1).
NOTE:
Incorrect adjustment of the insertion belt tension may give rise to noise, skewed insertion, envelope feed
faults or rapid wear of the loading roller.
Do not rotate the inserting roller by folding roller (6) (incorrect adjustment).
Take care not to soil or get grease on the inserting roller.
REVISION : 2.2
MENU
4.3.5 ENVELOPE BELT TENSION
PURPOSE: Make sure that the belt tension is correct.
- Remove gear wheel (1) from the envelope feed motor.
- Undo screw (2) fixing the tensionner in order to release it
- Drive the belt in the 2 directions by turning manually the pulley and gear wheel (3).
- While turning the pulley, tighten screw (2) in the tensionner lower position.
- Fit again the motor gear wheel.
NOTE:
An incorrect adjustment of the belt tension will result in difficulties in the envelope feeding, as well as in
insertion, closing and ejection defect. These defects will be accompanied by a typical knocking noise in the
motor.
REVISION : 2.2
MENU
4.3.6 FOLDING PLATES TEST
SUBJECT: Check the Folding plates management.
- PROCEDURE:
- Service menu access (see page 39) :
Press START key and the UP key , and keep pushing both keys while turning the
machine on.
Enter the access code:
SELECTION , UP , MEMORIZE , DOWN and START
- Open the machine (see page 6).

- Switch the top cover security MACHINE-OPEN with a screwdriver in order to have no risk to
forget the shortcut of this security.
- With the keyboard, select : Advanced parameters.
- Select Pocket life cycle.
- Press START to begin the test cycle:

. Feeder A stop bar (selection between automatic and daily mode).
. Pocket A deflector (only for the European machines).
. Folding plate stopper cycle test.
- At the end of the test, dont forget to remove the tool you have used to restore the top cover security.
REVISION : 2.2
MENU
5 DISASSEMBLING, RE-ASSEMBLING AND ADJUSTMENTS

5.1 TOOLS
DESIGNATION REF. FUNCTION

SEPARATION ASSEMBLY TOOL 4103791G Separation assembly adjustment.
GREASE OF SYNTHESIS
MULTIMETER Ohmmeter
T10 TORX Screwdriver
T20 TORX Screwdriver
Philips screwdriver Screwdriver
POSIDRIVE screwdriver Screwdriver
SPRING HOOK
VARNISH
5.2 DISASSEMBLING
5.2.1 DISASSEMBLING BASE COVERS
1- Remove the top cover (2 screws underneath the front) and 2 screws on the top at the rear. Do not forget
to remove the metallic cable holder above the display unit.
2- Remove the side covers fitted in the lower part. (3 screws for each)
3- Remove the lower cover (4 screws underneath the machine, through the 4 feet).
5.2.2 DISASSEMBLING MAIN PCB
1- Remove the top cover (refer to description chapter 5.2.1)

2- Disconnect the cables from the PCB
3- Remove the protection plate below the MAIN PCB (1 screw on the right)
4- Remove the MAIN PCB: 1 screw on the left in the middle of the board, 2 screws on the right side fixing the cooler).
The bottom one has just to be loosened.
PCB
screws
Screw
Protection
plate
REVISION : 2.2
MENU
5.3 RE-ASSEMBLING AND ADJUSTMENTS
5.3.1 REASSEMBLING TOP COVER
When putting back the top cover onto the machine, be careful to put the hopper side guides locking knob in regard of
the locking lever (set both to the locked position) otherwise the locking system will be out of order.
Locked position
REVISION : 2.2
MENU
5.4 FEEDER C SEPARATION ADJUSTMENT
To ease the adjustment it is possible to disassemble Feeder C.
5.4.1 TOOLS
DESIGNATION REF. FUNCTION

SEPARATION ASSEMBLY TOOL 4103791G Separation assembly adjustment.
5,5 mm spaner spaner
POSIDRIVE screwdriver Screwdriver
5.4.2 FEEDER C DISASSEMBLING
- Remove the two clips

- Slide the axle
- Take care of the sensor feeder C empty cable.
Be careful
Slide the axle
Two clips
5.4.3 FEEDER C ADJUSTMENT

- Adjusting tool
Adjusting shim to be nest between the axle

and the separation pad
REVISION : 2.2
- Undo the two nuts
Undo the two nuts
- Position the adjusting tool
Correct position of the adjusting

tool
- Stop the separation pad against the gauge.

- Tight the two nuts
- Repeat this operation for the second separation pad (on the left side of the feeder).
- Re-fix the Feeder (the axle and the two clips).
REVISION : 2.2
5.5 DISASSEMBLING AND RE-ASSEMBLING SUMMARY
COMPLETE
BASE
TOP COVER SIDE COVERS
RIBBON
CABLE FEEDER E LEFT LETTER
HOLDER GEARS METALLIC OUTPUT INSERTING
SENSOR ASS. PLATE
FLASH
MAIN PCB DOCUMENT
MEMORY FINGER
TRANSPORT
SHAFT
PATH GEARS
FEEDER E
GEERS
ENV-EXIT
SENSOR INSERTING
SIDE COVERS ROLLER
ASSEMBLY
FEEDER E ASSEMBLY
FRONT PLATE
FOLD
JACKS ROLLERS "2" LOWER COVER
FEEDER E & "3"
SEPARATION
PLATE
CAMS&INSER POWER POCKET B INSERT

SIDE GUIDE TING GEARS SUPPLY ASSEMBLY SIGNAL
LOCKING SENSOR
BRACKET ASSEMBLY
FEEDER E SIDE COVERS DISCONNECT FOLD POCKET A

TOP PLATE THE JACKS ROLLER 3 UPPER PLATE
FEEDER E
ROLLERS
TOP TABS
SPRING HOLDERS GUIDING THE
ALUMINIUM WHICH PULL THE
POCKET A & POCKET A
FOLD POCKET A
PATH C ASSEMBLY WHEN
ROLLER 1 ASSEMBLY WHEN
ASSEMBLY PIVOTING
OPENNING
REVISION : 2.2
MENU
6 THEORY OF OPERATION
6.1 KEY CODES
UP
DOWN
SELECT MEMORIZE ESC START
Service mode access:

Press the keys START and UP and keep pushing both keys while turning the machine on.
The access in code is: SELECT, UP, MEMORIZE, DOWN and START
Advanced Menu access (user):

Press ESC during the machine initialisation
To lock or unlock a job:

In the ready screen select the job and press ESC and while pressing ESC, press MEMORIZE.
To set the feeder A-B clutches timing:

In the ready screen, press ESC and while pressing ESC press UP
Information screen access:

In the ready screen, press ESC and while pressing ESC, press DOWN
RAM reset (EEPROM initialisation):

Press the keys START + MEMORIZE and keep pushing both keys while turning the machine on, press START and
while pressing START, press MEMORIZE.
REVISION : 2.2
MENU
6.2 USER MODE DIAGRAM
MACHINE
OFF
MACHINE TURNED ON
AUTHORIZATION This step appears until the

CODE SETUP Authorization code has not been set
USER MENU
COUNTER SET TO ZERO
JOB NUMBER START TEST CYCLE
ESC + MEM LOCK / UNLOCK
MANUAL A / MANUAL A+B / MANUAL

FEEDER A+C /MANUAL A+B+C / AUTO A+B /
AUTO A / AUTO A+B+C / AUTO A+C /
AUTO C
USA: LETTER 11" / LEGAL 14" / NOTE:

SPECIAL USA/EUROPE is set in
DOCUMENT Service mode (ADVANCED
EUROPE: A4 / 12" / A5 / SPECIAL PARAMETERS)
USA: SPECIAL SEAL / SPECIAL NO SEAL / C FOLD ONLY /

#10 SEAL / #10 NO SEAL
ENVELOPE EUROPE: SPECIAL SEAL / SPECIAL NO SEAL / C FOLD ONLY /
SINGLE FOLD ONLY / C6/5 - DL SEAL /
C6/5 - DL NO SEAL / C5 SEAL / C5 NO SEAL
ADDRESS
MOVE THE ADDRESS UPWARD
HEIGHT
MOVE THE EDDRESS DOWNWARD
REVISION : 2.2
MENU
6.3 SETTING MODE DIAGRAM (ADVANCED USER MODE)
MACHINE
OFF
ESC DURING INIT
MACHINE SETUP MENU ESC EXIT
FRANCAIS / ENGLISH / DEUTSH / ITALIANO / NEDERLANDS /

LANGUAGE
ESPANOL / SVENSKA / DANSK / PORTUGUES / POLSKI
SELECT THE SET - HEIGHT

SET ENV / DOC MEM ENVELOPE STANDART MEM - ENV POSITION
FORMAT ENVELOPE - MOIST. POSITION
SET - HEIGHT
SPECIAL MEM - ENV POSITION
ENVELOPE - MOIST. POSITION
SET
SPECIAL MEM SIZE
DOCUMENT
DOUBLE
DETECTION ENABLE / DISABLE THE DOUBLE DETECTION
BIN C
REVISION : 2.2
MENU
6.4 BASE SERVICE MODE
MACHINE
OFF
START + UP WHILE TURNING MACHINE ON
SET SERVICE
PIN CODE
SELECT - UP - MEM - DOWN - START
SERVICE MENU EXIT = OFF
SET MACHINE SERIAL

NUMBER NUMBER
START SETUP
C-CLOSED, ENV-EXIT,
SENSORS START MACHINE MACHINE-OPEN,
START
TEST SENSORS PART 1 EN-SEPARATION-C, C-EMPTY,
DOC-LOADED, INSERT-STOP
INSERT-SIGNAL,
MACHINE START LETTER-OUTPUT,
SENSORS PART 2 ENV-REFERENCE, CAM-ZERO
A-EMPTY, B-EMPTY,
FEEDER AB START END-SEPARATION-A,
SENSORS END-SEPARATION-B, DD-KEY
KEYBOARD TEST START KEYS TEST
SET TOTAL TOTAL COUNTER

START
COUNTER SETUP
SERVICE DOUBLE
SET DETECTION YES/NO
ADVANCED
PARAMETERS
SERVICE LIFE
CYCLE YES/NO
SET CONTINENT EUROPE/USA
CYCLE TEST FOR THE FEEDER A

POCKET LIFE START
STOP BAR, POCKET A
DEFLECTOR, AND POCKET STOP
CYCLE
BAR
SOFTWARE REFERENCE: 1.09 DOUBLE

DETECTION TEST
REVISION : 2.2
MENU
6.5 SEQUENCES OF SOFTWARE FUNCTIONS
MACHINE OFF
- MACHINE SWITCHED ON
THICKNESS SENSORS
INITIALIZATION
- THICKNESS SENSORS INITIALIZED
BOTTOM FOLDER
INITIALIZATION
- BOTTOM FOLDER INITIALIZED
TOP FOLDER INITIALIZATION
- TOP FOLDER INITIALIZED
CAM INITIALIZATION
- CAM AT THE "HOME" POSITION
MACHINE INITIALIZED
REVISION : 2.2
MENU
7 EUROPE SPECIFICATIONS
Maximum speed 1 350 envelopes/hour
automatic mode, opened or closed letter,
C6/5 env. and A4 document
Operating life 180 000 envelopes
Regular monthly volume 1000 envelopes
Maximum monthly use 3 000 envelopes
Maximum daily volume 3 000 envelopes
Maximum theoretical service life 5 years
MCBF (Mean Cycle Between Failures) 12 000 (failure = breakdown)
BVPY (Breakdown Visit Per Year) 1 VPY for 1 000 cycles average monthly use
MTTR (Mean Time To Repair) Maximum: 1h00
Selection rollers durability 120 000 cycles
Rollers cleaning in normal use 1 per year (Service operation)
Capacity of main document feeder

- bin A 100 sheets, 80 g
- bin B 100 sheets 80 g
Capacity of insert feeder
- bin C Reply envelopes: 100
Inserts 250 g : 200
Catch tray capacity : 100 letters (inserted with 2 A4 sheets, 80g, letter fold)
Water tank capacity about 1 000 letters
Types of folds - single fold
- Letter fold
- Double parallel fold
Capacity of folds/insertion
- Single/double fold weight 70 to 85 g/m 1 to 5 sheets
weight 86 to 120 g/m (1) 1 to 3 sheets
- Parallel fold weight 70 to 85 g/m 1 to 3 sheets
weight 86 to 120 g/m (1) 1 to 2 sheets
- Insertion without fold (from bin C) weight 80 to 250 g/m 1 sheet
up to 150 g/m for glossy paper in manual insertion.
Remark : Insert counts as one page in the fold and insertion capacity.
Dimensions of fold Tolerance on fold dimension 3 mm

- Single fold: min. 60 mm
max. 155 mm
- Double and parallel fold:

1st fold (A) : min. 65 mm
max. 155 mm
2nd fold (B) : min. 60 mm
max. 155 mm
REVISION : 2.2
SPECIFICATION (FOLLOW UP) MENU

Envelopes with and without windows
Width 224 to 240 mm
Height small 105 to 125 mm
Large (Europe only) 152 to 165 mm
Quality/thickness 75 to 90 g/m
These dimensions allow to process C6/5, DL, C5 envelopes

Documents (bins A and B)
Basic document: Europe: A4 (210 x 297 mm), 2/3 A4 (210 x 198 mm) and
A4(210 x 148.5 mm)
Other dimensions : width 142 to 226 mm

height 178 to 356 mm
Paper quality - main document, single and double
fold
Printers, Listings, Photocopiers, Offset 70 to 120 g/m (automatic and manual feeding)
st
Self-copier 70 to 120 g/m (1 sheet of self-copying stack automatic
and manual feeding)
Glossy paper (advertisement) () 90 to 120 g/m in automatic feeding mode
90 to 150 g/m in manual feeding mode
() A preliminary test can be required. This paper quality may require frequent pick-up rollers and fold rollers
cleaning.
Long size annex inserts (manual entry and bin B)
width :
height : 142 to 226 mm
80 to 150 mm
Paper quality - auxiliary inserts
Printers, Listings, Photocopiers, Offset 80 to 90 g/m
Selfcopier 70 to 90 g/m
Glossy paper (advertisement) () 90 to 120 g/m
- () A preliminary test can be required. This paper quality may require frequent pick-up rollers and fold rollers
cleaning.
- Auxiliary insert must be positioned behind a document and cannot therefore be seen through the envelope window.
Short size annex insert (bin C)

Dimensions :
width 142 to 226 mm
height 80 to 150 mm
Paper quality - Inserts

Printers, Listings, Photocopiers 80 to 120 g/m
Offset, Bristol board, Glossy paper (advertisement) () 80 to 250 g/m
Glossy paper (), Pre-fold
Business Reply envelopes (BRE) 90 to 170 g/m
70 to 90 g/m (with or without window)
() A preliminary test can be required. This paper quality may require frequent pick-up rollers and fold rollers
cleaning
REVISION : 2.2
8 USA SPECIFICATIONS
Maximum speed 1 350 envelopes/hour

Automatic mode, opened or closed letter,
# 10 env. and 8 1/2"x 11" document
Operating life 180 000 envelopes
Regular monthly volume 1000 envelopes
Maximum monthly use 3 000 envelopes
Maximum daily volume 3 000 envelopes
Maximum theoretical service life 5 years
MCBF (Mean Cycle Between Failures) 12 000 (failure = breakdown)
BVPY (Breakdown Visit Per Year) 1 BVPY for 1 000 cycles average monthly use
MTTR (Mean Time To Repair) Maximum: 1h00
Selection rollers durability 120 000 cycles
Rollers cleaning interval in normal use 1 per year (Service operation)
Capacity of main document feeder

- bin A 100 sheets, 20 Lb Bond
- bin B 100 sheets, 20 Lb Bond
Capacity of insert feeder
- bin C Reply envelopes: 100
65 lbs Inserts: 200
Catch tray capacity 100 letters (inserted with 2x 20 Lb Bond Letters sheets)
Water tank capacity About 1 000 letters
Types of folds - Letter fold and Double parallel fold
Capacity of folds/insertion
- Letter fold From 20 to 22 Lb Bond 1 to 5 sheets
From 24 to 32 Lb Bond 1 to 3 sheets
- Double parallel fold From 20 to 22 Lb Bond 1 to 3 sheets
From 24 to 32 Lb Bond (1) 1 to 2 sheets
- Insertion without fold (from bin C) From 20 to 66 Lb Bond 1 sheet
Up to 39 lbs for glossy paper with manual feeding.
Remark : Insert counts as one page in the fold and insertion capacity.
Dimensions of fold Tolerance on fold dimension 0,12 In. ( 3mm)

- Double and parallel fold:
1st fold (A) : min. 2,56 in. (65 mm)
max. 6,10 in. (155 mm)
2nd fold (B) : min. 2,36 in. (60 mm)
max. 6,10 in. (155 mm)
REVISION : 2.2
SPECIFICATION (FOLLOW UP)

Envelopes with and without windows
Width 8,82 in. to 9,45 in. (224 to 240 mm)
Height 4,13 in. to 4,92 in. (105 to 125 mm)
Quality/thickness 20 to 24 Lb Bond
These dimensions allow to process #10 envelopes and higher.

Documents (bins A and B)
Regular documents: Letter US ( 8 " x 11"), 8 " x 8" and 8 " x 5 " for
US.
Other dimensions: Width 5,6 in. to 8,9 in. (142 to 226 mm)
Height 3,15 in. to 14 in. (80 to 356 mm)
Paper quality - main document, single and

double fold
Printers, Listings, Photocopiers, Offset 20 to 32 Lb Bond (automatic and manual feeding)
Self-copier 20 to 32 Lb Bond (1st sheet of self-copying stack
automatic and manual feeding)
Glossy paper (advertisement) () 24 to 32 Lb Bond in automatic feeding mode
24 to 32 Lb Bond in manual feeding mode
() A preliminary test can be required. This paper quality may require frequent pick-up rollers and fold
rollers cleaning.
Long size annex inserts (manual entry and
bin B)
Paper quality - auxiliary inserts
Printers, Listings, Photocopiers, Offset 20 to 24 Lb Bond
Self-copying (NCR) 19 to 24 Lb Bond
Glossy paper (advertisement) () 24 to 32 Lb Bond
- () A preliminary test can be required. This paper quality may require frequent pick-up rollers and fold
rollers cleaning.
- Auxiliary insert must be positioned behind a document and cannot therefore be seen through the
envelope window.
Short size annex insert (bin C)

Dimensions:
Paper quality - Inserts

Printers, Listings, Photocopiers 20 to 32 Lb Bond
Offset, Bristol board, Glossy paper (advertisement) 20 to 66 Lb Bond
()
Glossy paper (), Pre-fold 19 to 45 Lb Bond
Business Reply Envelopes (BRE) 19 to 24 Lb Bond (with or without window)
() A preliminary test can be required. This paper quality may require frequent pick-up rollers and fold
rollers cleaning
REVISION : 2.2
MENU
9 RECOMMENDED SPARE PARTS LIST
Qty / 1000 machines / year

High volume
S1 Regular cust.
Part cust. (3000
compat French description English description (1000 cycles
number . cycles /
/ month/ 5
month/ 5
Years)
Years)
11BFA1105 YES Ampoule reed (C-FERME) Reed sensor assembly (C-CLOSED) 2 3,6
11PIA0101 YES Barette selection bac E (Europe) Hopper separation plate (Europe) 2 3,6
11PIC0202 YES Barette selection bac E (US) Hopper separation plate (US) 2 3,6
11PIC0082 YES Tle insertion Inserting plate 10 18
11PIC0178 YES Dflecteur sortie enveloppe Deflector - Letter exit 30 54
11PID0075 YES Rouleau pliage N1 (ALU) Folding roller (alu) 2 3,6
12PIC0006 YES Vrin Jack 100 180
4105487Y YES Guide arrire gauche bac E Hopper rear guide (left) 10 18
4105488Z YES Guide arrire droit bac E Hopper rear guide (right) 10 18
4105489A NO Flasque droit bac C Cover - bin C (right) 10 18
4105490B NO Flasque gauche bac C Cover - bin C (left) 10 18
4105492D YES Bouton verrouillage bac E Hopper side guides locking knob 10 18
4105505S NO Capot sortie inf Cover - Letter exit (lower part) 5 9
4121894P NO Moteur bac E quip Hopper motor 5 9
4121897S NO Moteur quip Env / Came Env / Cam transport motor 5 9
4121907C NO Moteur transport doc quip Main motor 5 9
4121955C NO Ensemble ecran clavier User interface assembly (display unit 10 18
+ keyboard + PCB)
4121956D NO Capot afficheur Cover - Display 10 18
4122058K NO Capot support guides arrires bac E Cover - Hopper rear guides bracket 5 9
4122061N YES Margeur gauche bac E Hopper side guide (left) 5 9
4122062P YES Margeur droit bac E Hopper side guide (right) 5 9
4122113S NO carte principale Main PCB 20 36
4122148D NO Plateau magasin env. Hopper plate 5 9
4122525W NO Platine avant bac E Hopper front plate 5 9
REVISION : 2.2
MENU

High volume
S1 Regular cust.
Part cust. (3000
number . cycles /
/ month/ 5
month/ 5
Years)
Years)
4122745A NO Limande afficheur Cable (display PCB) 100 180
4122748D NO alimentation Power supply assembly 5 9
4122972M YES Ensemble bac C quip Europe Bin C assembly for Europe 1 1,8
4122973N YES Ensemble bac C quip US Bin C assembly for USA 1 1,8
4122988D NO Ensemble commande de bute de Pocket stop drive assembly 1 1,8
poche
4122989E NO Ensemble tle infrieure poche A Pocket A Lower plate assembly 1 1,8
quipe
4122990F YES Ensemble chemin encart (sup + Inf) Insert path assembly (upper + lower) 1 1,8
4122993J NO Ensemble tle infrieure poche B Pocket B Lower plate assembly 1 1,8
quipe
4122999Q YES ensemble bac mouilleur Moistener tank assembly 15 27
4124580M YES* Kit ensemble arrt enveloppe Kit - Envelope stop assembly 5 9
4124581N YES Kit 3 brosses de mouillage Kit - 3 moinsting brushes 15 27
4124582P YES Kit cames Kit - cams 5 9
4124583Q NO Kit capteurs Kit - sensors 80 144
4124584R YES Kit courroies Kit - belts 5 9
4124585S YES Kit embrayages Kit - clutches 10 18
4124586T YES** Kit fermeture poche A (Europe Kit - Pocket A closing (Europe only) 3 5,4
seulement)
4124587U YES Kit insertion (Europe) Kit - Inserting (Europe) 3 5,4
4124588V YES Kit languettes Kit - tongues 30 54
4124589W YES Kit leviers defleteur sortie envelopes Kit - Envelope exit lever deflector 25 45
4124590X YES Kit maintenance bac C Kit - Feeder C maintenance 25 45
4124591Y YES Kit maintenance bac E Kit - Feeder E maintenance 30 54
4124592Z YES Kit maintenance chemin encarts Kit - Inserts path maintenance 10 18
REVISION : 2.2
MENU

High volume
S1 Regular cust.
Part cust. (3000
number . cycles /
/ month/ 5
month/ 5
Years)
Years)
4124593A YES Kit maintenance pliage Kit - Folding maintenance 3 5,4
4124594B YES Kit maintenance transport documents Kit - Documents transportation 10 18
maintenance
4124595C YES Kit pignons bac C Kit - Feeder C gears 50 90
4124596D YES Kit pignons bac E Kit - Feeder E gears 50 90
4124598F YES Kit pignons insertion Kit - Inserting gears 50 90
4124599G YES Kit pignons transport documents Kit - Documents transportation gears 100 180
4124600H YES Kit pignon transport envelopes Kit - Envelope transport kit 50 90
4124602K YES Kit ressorts Kit - Springs 50 90
4124603L YES Kit maintenance rouleaux de sortie Kit - Exit rollers maintenance 10 18
4124604M NO Kit cbles Kit - Cables 15 27
4124648P YES Kit boutons alimenteur AB Kit - Feeder AB knobs 100 180
4124831Y YES Kit insertion (US) Kit - Inserting (US) 5 9
4125899L NO Ensemble alimenteur AB Feeder AB assembly 30 54
* Le capteur 4122298K inclu dans ce kit The sensor 4122298K included in this kit is not compatible with S1
n'est pas compatible S1
** Le moteur 4121971U inclus dans ce The motor 4121971U included in this kit is tot compatible with S1
kit n'est pas compatible S1

SI-30 Info.

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ISSUE : 29/10/04 SI30 / M1000 / CARAT XS SERVICE MANUAL

8 USA SPECIFICATIONS .....................................................................................50

9 RECOMMENDED SPARE PARTS LIST............................................................52

Never grease ball bearings.

Empty the water tank before transporting the machine.

Grease: MOLYCOTE PLASTISLIP PG75 (plastic parts)

A SELECTION See description in Section 1, Chapter 1.4.1 "Sensors"

Fix: Job memorized Job secured (locked)

Single fold C fold or letter fold Double parallel fold

DD-A DD-B END SEPARATION - B END-SEPARATION-A

DD-KEY A-EMPTY / AUTOSTART B-EMPTY

C SELECTION C TRANSPORT CLUTCH DOCUMENT FEEDER

MACHINE SENSORS (PART 1)

LEFT INTENTIONALLY BLANK

2 SERVICE CALL CHECK LISTS

2.1 START OF SERVICE CALL CHECK LIST

Check the user has been trained on the machine.

2.2 END OF SERVICE CALL CHECK LIST

Clean the transportation and folding rollers.

2.3 PREVENTIVE MAINTENANCE

SPARE / KIT PN REGULAR "HIGH VOLUME" CUSTOMER

2.4 MAINTENANCE KITS DETAILS

Kit description Series 1 Part Quantity French description English description

KITS DETAILS (FOLLOW UP) MENU

KITS DETAILS (FOLLOW UP) MENU

KITS DETAILS (FOLLOW UP) MENU

KITS DETAILS (FOLLOW UP) MENU

KITS DETAILS (FOLLOW UP) MENU

KITS DETAILS (FOLLOW UP) MENU

KITS DETAILS (FOLLOW UP) MENU

3 SOFTWARE UPGRADE AND CPU BOARD REPLACEMENT

1 Switch off and unplug the machine

3.2 CPU BOARD REPLACEMENT

Perform a RAM Reset

Message displayed Likely Cause Remedy

Message displayed Likely Cause Remedy

NO DOCUMENT IN THE Sensors faulty Check the sensors in the service

4.2 FUNCTIONAL FAULTS

SYMPTOMS Likely Cause Remedy

4.3 FUNCTIONAL TESTS

- Remove the upper cover.

TOP INSERTING PLATE UPPER DEFLECTOR EDGE

- A & B CLUTCHES SETTING PROCEDURE:

- Use the arrow key to select the line job number,

- Use the same process for clutch B.

Note: the value reference is written underneath the feeder A-B

4.3.3 CAM POSITION AND CAM BELT TENSION

PURPOSE: To ensure that the belt tension is correct.

PURPOSE: Make sure that the belt tension is correct.

4.3.6 FOLDING PLATES TEST

SUBJECT: Check the Folding plates management.

- Service menu access (see page 39) :

Enter the access code:

SELECTION , UP , MEMORIZE , DOWN and START

- Open the machine (see page 6).

- Press START to begin the test cycle:

5 DISASSEMBLING, RE-ASSEMBLING AND ADJUSTMENTS

DESIGNATION REF. FUNCTION

5.2.2 DISASSEMBLING MAIN PCB

1- Remove the top cover (refer to description chapter 5.2.1)

To ease the adjustment it is possible to disassemble Feeder C.

DESIGNATION REF. FUNCTION

5.4.2 FEEDER C DISASSEMBLING

- Remove the two clips