WinSystems SAT-520PLUS Manuel de service

420T V6LT OPERATOR & SERVICE MANUAL ISSUE 01/2010 Rev. 6/21/2011 COVER071-33370-400GBR Systems Corporation 12 Inspiration Lane Chester, CT 0641

While every care has been taken in the preparation of this manual, noliability will be accepted by GBR Systems Corporation arising out of anyinaccurac

WHAT HAPPENEDCycling, a pack reached Xfer Station 3, but the pack from Xfer Station 2has no data.ACTION TO TAKEHad the Xfer Station 2 pack previously

15055 " Data Overwrite Sta 4 - Set Sta 4 Pack Bad”HARDWARE: New Xfer Conveyor, Bridge and Two StageWHAT HAPPENEDCycling, the pack data reached X

ANY OTHER ADJUSTMENTSThis pack was marked bad.Was there an Xfer Conveyor error in the previous cycle?Remove and inspect this pack and other suspect pa

C.3g (16xxx or 18xxx) Reader 16052 “READLESS READ ERROR ”(NN=16 BAR READ MESSAGES OR NN=18 LINE READ MESSAGES)Bar Code Reading ErrorsError Descript

nnn07 “INVALID GROUP”Group is not part of set.Check to see that the proper barcode is printed on the page and that thebarcode matches the specificati

nnn17 “INVALID PIC INT” (Invalid "Programmable Interrupt Controller" interrupt)Hardware failure on reader boardBattery failed or battery ju

nnn29 “EXPECTED READING”Blank pageRead encoder failedPaper jamFeed sensor out of adjustmentnnn30 “READER REBOOTED”Reader encoder failedBad read boar

Make sure that the barcode print on the paper is good quality.nnn42 “MAX PAGE NOT = NO. PAGES” (Bar Reading)Incorrect page count in accumulatorPage c

nnn56 "SETUP TIMEOUT ERROR"nnn57 "NO READ DATA"nnn99 "UNDEFINED ERROR"C.3h (17xxx) Inserter Error Messages Error D

The following pictures are intended to be helpful in the procedure forcorrecting a malfunction of the E-Stop System.1. Check the 24VDC at F1A, page

SECTION A INTRODUCTIONA.1 INTRODUCTION TO THE MANUALThis manual is intended for service technicians and is organized to enhancepreventive maintenance

4. If all check ok, could be a bad guard module, contactor for switch ACand DC could have a bad contact on aux contactor module located ontop of the

GBR 420 Inserter Screen List Diagnostic DescriptionOverview:The GBR 420 Inserter Interface passes a pack to the inserter track at anopen station or a

Position: ‘c’ is Envelope, Inkmark(Kick, Postal Sort), Divert weighted as 1,2, 4 and added. 0 to 7.Div. Ink. Env. 'c'0 0 0 00 0 1 10 1 0 20

420T/438 - Barcode Data Specification 3 - 2D - Rev.3OverviewThis document outlines a simple specification using a standard 2D DataMatrix Barcode. Thi

0 = disable; 1 = enableBit 3 – inserter station 3 select 0 to 10 = disable; 1 = enableBit 4 – inserter station 4 select 0 to 10 = disable; 1 = enableB

PmDivert CodeStart=0 Length=0 Start_Bit=0BARREAD SETUP3Total Page Code Start=0 Length=0 Start_Bit=0Length_Bit=0Seq. Stop Code Start=0 Start_Bit=0Subse

Example1:PageGroupSeq.PageSeq.Ink/ZipMarkEnd ofGroupInsertsEnabledBarcode Description1 05 1 disabled Yes #4 1051801234567890123456Group 5, page 1, Cus

Tables420T V6LT OPERATOR & SERVICE MANUAL ISSUE 2009/06 Rev. 6/21/2011 SECTION C – PAGE 117071-33370-400BarCode Character to Value to 5-Bit Valu

M22 16 1 0 1 1 0N23 17 1 0 1 1 1O24 18 1 1 0 0 0P25 19 1 1 0 0 1Q26 1A 1 1 0 1 0R27 1B 1 1 0 1 1S28 1C 1 1 1 0 0T29 1D 1 1 1 0 1U30 1E 1 1 1 1 0V31 1F

To define the Extraction of Demand Feed:Char. Position 1 2 3 4 5always start at 1 and count up from left to right.1 8 9 0 9 for this example.Define De

Hopper and Feeder Paper Guide Rails:The two stainless steel rails mounted on the sides of the creeper conveyor are adjustable via a locking handle at

1 8 9 0 9for this example.Define Insert Start = 1Define Insert Length = 5 Must use the entirenumber.Demand Feed Data Extracted = “18909” “18909” is

Length (0 to 20). Number of characters. Used with Normal-A orReverse-A, multiple character numeric values,Start_Bit (0 to 20). (1 to 30)Starting bi

S 28 1C 011100T 29 1D 011101U 30 1E 011110V 31 1F 011111W 32 20 110000X 33 21 110001Y 34 22 110010Z 35 23 110011- 36 24 110100. 37 25 110101Space 38

• Demand Feed First Page does not expect a Demand Feed Mark onpages other than the FIRST page fed.(“UNEXPECTED EOG”).• EOG Mark At defines where the D

• This is a mark only on the first page fed. All other pages no mark.• Demand Feed Code defines where the BOG bit is.Group Change• This recognizes a

D.1 CPU PC104 (SAT520) CARDGBR Part Number: 042-31117-500D.1a FeaturesVideo, I/O, up to 4 Serial Interface (RS232 Ports), two floppydrive interface, I

D.2 I/O 96 Daughter CARDGBR Part Number: 042-31578-500D.2a General DescriptionSAT-520 Daughter Card installed as (2 x 48 I/O (two cards stacked)or 1 x

D.3b LED Indications:The following LED indications apply only when using BB+H line code.• LED 1 ON/OFF every second indicating operation (except when

D.6 Line Code Read CardGBR Part Number: 042-26908-500This card is mounted separate from the rest of the computer but isconnected with cables. The re

SECTION E. INTERFACE TO INSERTING EQUIPMENTThe 420T is designed to be run on-line with the inserter. It can be docked toany of the insert stations, h

420T V6LT OPERATOR & SERVICE MANUAL ISSUE 2009/06 Rev. 6/21/2011 SECTION A – PAGE 12071-33370-400INTRODUCTION420T Feeder Components

This is the zero, ‘0’, degree position, the Inserter Home position.• Note the Degree Display is 0 when the gripper arm is fully into the pocketIF NOT

• 4. Jog the inserter slowly through one cycle, observing mount closely.You will notice that as the mount swings downward it will bottom againstthe sh

• 3. Install switch block on small shaft, with the switch to the top, rear.Looking end on, block should have 5 degree tilt towards other shaft. Ifsha

E.3 Transfer Conveyor AdjustmentsE.3a Package overhang at last stationWhen a package is being presented to the gripper arm (last station of theTrans

• 4. The Transfer conveyor will index in response to the Dump command. Ifthe package that was placed just before the exit sensor stops at thedischarge

F.1 Software Rev Update using E-MailThe disk for the New438/420T is specifically bootable on the New438/420T.This boot software is not normally visib

F.3 Read Zone Diagrams:420T V6LT OPERATOR & SERVICE MANUAL ISSUE 2009/06 Rev. 6/21/2011 SECTION F – PAGE 136071-33370-400MISCELLANEOUSLine Code

F.4 Engineering ValuesThese values are to be used as a starting point. These values may vary,depending on type and weight of paper being processed, e

19 0“Test ExitComm Test List Switch” (Range: 0 >255, Inc: 1)0 = No extra ExitComm (Comm3) list messages. 1 =Extra ExitComm list messages, times i

37 0“Exit comm. Xmit Retries” (Range: 0 > 2, Inc: 1)1 + Default. In Tampa 1 only, if no Ack Response isreceived defined in EV#36, a retry is initi

Feed BeltThe Main Feed Belt is a one inch wide tan timing belt which drives thebottom sheet of paper under the singulator roller. Also called Singulat

50 0“ReadLess Read Mode” (Range: 0 > 1, Inc: 1,Default = 0)0 = Default. Normal operation.1 = Special error recovery routine when using Demand Fee

F.5 Typical Postal Metering Setup PresetsThe following are ‘Typical Presets’ for the 438 configured for 6-StationAC/DC Open Feed Inserter Control wit

Feeder Speed EncoderA blue-clad optical encoder located on the right side of the upper pulloutshaft. It is used to detect feeder run speed.A.2c ACCUM

Feed ClutchAn electrical clutch that engages the feed belt by a signal from the controller.Feed BrakeThe Feeder Brake and clutch work together to prov

Double Detect SensorThe double detect sensor is an ultra sonic sensor that does not requireelectrical adjustment. The mechanical position of the sens

Folder RollersUsed to nip the paper as it is buckling, creating the fold.Folder Drive Motor & Controller BoardA 110VAC motor that is controlled by

Folder Speed EncodersThere are two folder speed encoders. The one seen in the picture below isused to report the folder speed to the operator/mainten

Table of ContentsSECTION A INTRODUCTION ...10A.1 INTRODUCTION TO THE MANUAL ...10A.2 INTRODUCTION TO THE MACHINE...10A.2a

A.2e Components of the Controller BoxDC Power Distribution Chassis:With cover removed you can see The DC Power Distribution Chassis, theComputer Chas

Connections of the DC Power Dist. Chassis are detailed here for clarity.This picture of the DC Distribution Chassis show typical connections andvalues

Master Control Relays: Electric safety interlock switchInside The DC Distribution Chassis:Inside The Computer Chassis:Please pay regards to the warnin

Transfer Conveyor SensorsThese sensors monitor the flow of paper into and out of the transferconveyor. The Station 1 sensor checks to see that a fold

A.2f EMERGENCY STOP INTERLOCKSThe main E-stop located on the operator panel will interrupt power to theconveyors and folder when pressed down. All m

Under the cover located over the accumulator sectionOn the top cover of the folder.420T V6LT OPERATOR & SERVICE MANUAL ISSUE 2009/06 Rev. 6/21/20

On the lower cover under the (#2 & 4) buckle platesOn the folder and transfer conveyor meeting point (interrupts power whenthe transfer conveyor i

A.3 Machine SpecificationsListed below are specifications for the 420T:ThroughputSpeed: Max. 24,600 documents per hourMaterialPaper Weights: 20# (75

GBR Line CodeBar Code (3 of 9), (2 of 5) (128)A.4 RUN SCREENThis screen is displayed continuously for informational purposes until “Test”or “Setup”

A.5 KEYBOARD OPERATIONRUN / STOP• Press to start motors and enter ready mode.• Press while in ready mode to shut down the 420T.• (Press E-Stop to shu

A.6a System Setup ...29A.6b Feeder Setup ...31A.6c Accumulator Setup ...32A.6d Folder Set

A.6 SETUP SCREENSNote: The exact screens and functionality are software version dependent.Specific features may be available or not, or have default

stops feeding, purges the accumulator and transfer conveyor to the inserter,then powers down automatically.Sheet Length:• Double Arrow Up” button incr

A.6b Feeder SetupDouble Detect Select:• Select to have the 420T detect double feeds. Indicate Optical orUltrasonic.• Deselect if paper stock is causi

A.6c Accumulator SetupAccumulator Max:• Default = 8. Select up to 14 sheets maximum. The 420T will shut down ifmore than 14 sheets are fed into the

A.6e Xfer Cvyr (Transfer Conveyor) SetupExit Device Type:• XferCvyr-1(default) or Coll-1Xfer CvyrN:• Off to select old style Transport Conveyor (no i

A.6f Infeed SetupInfeed Type:Off:• When no infeed device is used.Creeper:• Select when using the Vacuum Loader or the Friction Feeder CreeperConveyo

Off Delay – Time:• This timer value is the period of time after the 420T has been stopped (bypressing the Start/Stop key) that the system waits for th

• Enables viewing the version of line code reader software. Also verifiescommunication with read board if a version is returned.OMR Sensors• Enables

1-05 = Separation Sol #1 Inserter P Data Bit #21-06 = Separation Sol #8 Inserter P Data Bit #31-07 = Shingle Conv Motor Inserter P Kicker1-08 =

Inserter Control Module. When the pack aligns with an Insert station thatit is supposed to get an insert from the ‘<‘ changes to the number of the

Addendum II...65Signal Specification ...651) RR Donnely 1 Protocol: ...652) RR Donnely 2 Pro

Bad Pack Stop:• This box is defaulted “on” or “checked.” The machine will stop on a badpack and enable the bad pack indicator light on the inserter.

Example of “Inserter Station Swapping” set-up on theGBR• Example: If you want a decode for insert feeder 4 to pull from insert feeder 1 set 1 = 4• If

A.6k Inserter Setup 2Envelope Station Vacuum:• Normally enabled at “230.” This is the position of the encoder (indegrees) at which vacuum is applied

A.6l Inserter Setup 3PM Divert, Postal Meter 2, and Postal Meter 3:• NOTE ON POSTAL METER WEIGHING: The 420T can accommodateup to three postal meters

Enter the weight of each insert in stations 1-6 and stations 7-12A.6m Inserter Setup 4Pause Degree:Pause Type: Switch or Degree• The defaults of On

A.6n Engineering Values (Password Protected)The above screen permits adjustment of the Engineering Values of programcontrol and machine parameters.

• Press Ok on the keypad to accept input and move to the next Engineering Value Number.A.6o Exit Comm SetupType:• 0 No Comm• 1 Spec D1• 2 Spec D2• 3

A.7 GBR LINE CODE READ SYSTEMS OPTIONA.7a IntroductionThe Line Code Recognition System is capable of decoding line code marksthat are on 1/8" o

A.7b 420T Line Read Setup Screens (GBR & BB+H)Line Read Setup 1(“Setup” > “Line Read” > “Setup 1”)DEMAND FEED:NORMAL - The machine will end

The purpose of the Group Set mark is to ensure pages from two differentpackages do not get processed in a single package. Group Set marks mustbe prese

C.3d (12xxx) Feeder ...8312001 “No Feed Error” ...8312020 “DOUBLE PAGE FED” ...8412021 “

Line Read Setup 2(“Setup” > “Line Read” > “Setup 2”)Lines / Inch:The code marks can be at 1/6, 1/8, or 1/10 inch spacing. This is 6, 8, or 10lin

GS4 GS2GS8 GS1PS1 PS4PS2 PS2PS4 PS1PAR PARLine Read Setup 3( “Setup” > “Line Read” > “Setup 3”)To Begin:The reader must be told at what point in

EOG At Mark:• Purpose - Controls the size of dynamic packages by indicating the end ofa group. • Usage - A solid bar is placed in this location on the

A.8 LASER BAR CODE READ OPTIONA.8a Laser SafetyTo prevent possible exposure to laser light that may exceed the CDRH’sAccessible Emission Limit for a

A.8b Bar Code BasicsA bar code is a group of rectangular bars and spaces arranged in a presetpattern. The pattern is organized to represent elements

A.9 Setting the 420T to Read Laser Bar Code“Setup” > “Bar Read”Modifications to the bar setups are retained as long as the bar job defaultsare not

Bar Read Setup 1Demand Feed:Normal• Mark is on the last page fed. Last page is “1” all others in the pack are “0”.Reverse• If checked, will handle an

Purpose - Identify each individual page within a package. The sequentialincrementing of the number ensures the documents are assembled in theproper or

Bar Read Setup 2The software permits a total of 30 characters in Bar Read, however,physically that isn’t always practical due to the length of the cod

Bar Read Setup 3Total Page Code:• Start (0 to 30). Start character.• Length (0 to 5). Number of characters.• For bit management use the following.•

15041 “False Feed Out Of Xfer Station 1”...9615042 "False Feed Into Xfer Station 2” ...9715042 “False Feed Into Xfer St

Bar Read Setup 4ReadFeed Type:• Feed&Read – When it is desired to Feed first and then Read (normal)• Read&Feed – When it is desired to Read be

ADDENDUM IOverviewThis document outlines the setup of the Postal Meters, Weight Calculationand Operation of Postal Metering on the GBR 420T.Note: The

• Enter Meter “OFF AT:’ in degrees, 0 to 350. Before 90 degrees.• Enter Meter Position ‘STA:• 1 to 12 after envelope insert station.• ‘0’ to Disable t

Weight CalculationPostal Meter Selection Calculation. Done when pack is transferred to theInserter.Package Weight = Envelope Weight + (No. Pages * Pa

Inserter Setup 3:• Postal Meter 2• 240. Meter “ON AT:’ in degrees.• 10. Meter “OFF AT:’ in degrees.• 6. Meter Position ‘STA:’ (6 stations after env

Two Meter Example Meter 1 to 2 Weight Break Value = 99. Must be greater than any packexpected.Meter 2 to 3 Weight Break Value = 20Package Weight Mete

based on the ‘ON AT’ degree for each meter. The first meter in line tested at 200 degrees. The second meter inline required some delay and wastested

• End of Bag. NA.6 ‘0’ - ‘9’ ASCII numbers 0 to 9, 30 hex to 39 hex. Barcode character 6 • Future NA..7 CR ASCII Carriage Return, OD hexNotes• Chara

3) Pinnacle 1 Protocol:Character Data Description1 ‘0’ -’7’ ASCII numbers 0 to 7, 30 hex to 37 hex.• Bit 0 = Station 1• Bit 1 = Station 2• Bit 2 = Sta

• Bit 0 = 0• Bit 1 = Sequential Stop Clear Accumulator Pack• Bit 2 = Sequential Stop Stop and Retain Accumulator Pack6 ‘0’ – ‘7’ ASCII numbers 0 to 7,

nnn28 “UN-EXPECTED RESPONSE” ...105nnn29 “EXPECTED READING” ...106nnn30 “READER REBOOTED” ...106nnn31 “C

• Bit 1 = Station 2• Bit 2 = Station 32 ‘0’ —’7’ ASCII numbers 0 to 7, 30 hex to 37 hex• Bit 0 = Station 4• Bit 1 = Station 5• Bit 2 = Station 63 ‘0’

6 ‘0’ - ‘7’ ASCII numbers 0 to 7, 30 hex to 37 hex.• Bit 0 = Postal Sort Mark, Ink Mark, Kick Mark, Envelope Mark• Bit 1 = Divert by Read Mark, Divert

3 ‘0’ - ‘7’ ASCII numbers 0 to 7, 30 hex to 37 hex.• Bit 0 = Station 7• Bit 1 = Station 8• Bit 2 = Station 94 ‘0’ - ‘9’ ASCII numbers 0 to 9, 30 hex t

• Station 3 = 1• Station 4 = 0• Station 5 = 1• Station 6 = 0• Station 7 = 1• Station 8 = 0• Station 9 = 1The selected protocol formats the test data a

SECTION B PREVENTATIVE MAINTENANCEB.1 Test equipment and tools• ·Portable Scope Meter• ·Standard & Metric Hex Wrenches• ·Small Blade Flat Screwdr

C.1 “TEST” SCREEN OPERATIONDiagnosis of the system begins with these tests. If it is found that thedisplayed information indicates a problem, refer t

To help understand the "Input/Output (I/O) Test" screen it needs a littleintroduction. We will concentrate on only the block of numbers on

C.2c I/O Reference Tables 420 V6LT I/O Table 1RackOpto Type Description1 00 Output Feed Clutch1 01 Output Folder Motor1 02 Output Feed Motor1 03 Out

C.3 GENERAL SOLUTIONS TO ERRORSMany error codes are the result of jammed paper (physical errors), or paperexpected at specific time and location (rea

C.3b ERROR CODESEach error is displayed using a combination of numbers that are coded togive the operator/maintenance personnel an idea of where to

420T/438 - Barcode Data Specification 3 - 2D - Rev.3 ...113Overview ...113Bar Code Description ...1

Feeder Module: 120nn/8nn12001 "Feeder; No Feed Error”12020 “DOUBLE PAGE FED”12021 "Below Minimum Speed"12022 “LONG PAGE FED”12023 “EXTR

15026 "Unkown Pack Sta 1 - Set Pack Bad"15027 "Unknown Pack Sta 2 - Set Pack Bad"15028 "Unknown Pace Sta 3 - Set Pack Bad&quo

21005 “IF-42 Conveyor Output Paper Jam - Clear Jam”21006 “810 Right Angle Not Ready - Check Power”21007 “IF-42 Conveyor In/Out Paper Jam - Clear Jam”2

C.3c (11xxx) SystemError Description11020 “Exit Demand Timeout”When a package in the accumulator does not leave the accumulatorwithin a given time

12020 “DOUBLE PAGE FED”WHAT HAPPENEDThe Double Page sensor sensed more than one page as it was fedthrought the sensor.For an optical sensor: The sens

12023 “EXTRA PAGE WAS FED”WHAT HAPPENEDThe Feeder was not processing a page feed, did not expect a page fedand sensed a page fed at the Feeder Sensor

C.3e (13xxx) AccumulatorError Description13000 “Stack Error”WHAT HAPPENEDA sheet entering the Accumulator, has not entered the accumulator rampsen

13021 “Un-Expected Pack Present - Remove Pack”WHAT HAPPENEDThe machine was powered up with a pack in the accumulator beingsensed by the accumulator s

sensor plus the current number of pages collected in the inserter tracksection would exceed the maximum number of pages that can becollected in the in

14021 "Folder Exit Sensor Jam"HARDWARE: Accum Type=Flats, System Exit Device=Conveyor,System Exit Device=Xfer,Xfer XcvyN=ON. WHAT HAPPENEDC

F.3 Read Zone Diagrams: ...136F.4 Engineering Values ...137F.5 Typical Postal Metering Setup Presets ...141Test - “

15003 “Jam At Out Sensor Error”HARDWARE: Original Xfer ConveyorWHAT HAPPENEDCycling, a pack did not leave the Xfer Conveyor Out Sensor within a time.

Adjust Engin Value#7 Xcvy Clutch On Time to place 3 packs evenly inthe Original Xfer Conveyor.—The last pack should be about 1 inch from the exit roll

15022 “Jam into Xfer Station 2”HARDWARE: New Xfer Conveyor, Bridge and Two Stage15022 “Jam Into Xfer Station 2"WHAT HAPPENEDCycling, a pack did

Set Engin. Value#55 to 1 to set all packs in the Xfer Conveyor bad.The following device, maybe an Inserter, may have provision to divert badpacks for

The following device, maybe an Inserter, may have provision to divertbad packs for inspection.15028 “Unknown Pack Sta 3 – Set Pack Bad”HARDWARE: New

15032 “Jam Out Of Collector”HARDWARE: CollectorWHAT HAPPENEDCycling, a pack did not leave the Collector within a time.ACTION TO TAKECheck for a jam a

15038 “Missing Pack Sta 3 – Set Sta Empty”HARDWARE: New Xfer Conveyor, Bridge and Two StageWHAT HAPPENEDAt Power On, Motors On, a pack was not sensed

Test the clutch and brake at Station 1.ANY OTHER ADJUSTMENTSDid this pack stop under the Station Sensor? Adjust sensor, turn XferConveyor speed down,

ACTION TO TAKETest the sensor at Station 2.Test the clutch and brake at Station 2.ANY OTHER ADJUSTMENTSDid this pack stop under the Station Sensor? A

Xfer Station 4 is a data holding location for data passed to an exit devicesuch as an InserterACTION TO TAKEHad the Xfer Station 2 pack previously ent