Pitney Bowes DA80F Manuel utilisateur

Service Manual

DA80F and DA95F

AddressRight™Fixed Head Printers

DA80F (WF81)

DA95F (WF96)

FCC Compliance

This equipment had been tested and found to comply with the limits for a Class A digital device,

pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection

against interference when the equipment is operated in a commercial environment. This equipment

generates, uses, and can radiate radio frequency energy, and if not installed and used in accordance

with the users manuals, may cause harmful interference to radio communications. Operation of this

equipment in a residential area is likely to cause harmful interference in which case the user will be

required to correct the interference at his own expense.

Shielded cables must be used with this unit to insure compliance with Class A limits.

Canadian DOC Compliance

This digital apparatus does not exceed in the Class A limits for radio noise emissions from digital ap-

paratus set out in the Interference-causing Equipment Regulations (Standard ICES-003) of the Ca-

nadian Department of Communications.

Le present appareil numerique n’emet pas de bruits radioelectriques depassant les limites appli-

cables aux appareils numeriques de la class A prescrites dans le Reglement sur le brouillage radio-

electrique edicte par le ministere des Communications du Canada.

NOTE: This equipment has been tested and found to comply with the U.S. Standard for Safety

UL1950, Third Edition, Safety of Information Technology Equipment including Electrical Business

Equipment and Canadian Standards C22.2 No 950-95, Third Edition, Safety of Information Technol-

ogy Equipment including Electrical Business Equipment

First Edition, December 2007

SV61962 Rev. A

retrieval system of any type or transmitted by any means, electronically or mechanically, without the

express written permission of Pitney Bowes Inc.

We have made every reasonable effort to assure the accuracy and usefulness of this manual, how-

ever, we cannot assume responsibility for errors or omissions or liability for the misuse or misappli-

cation of our products.

Table of Contents

DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A) iii

Chapter 1 – Introduction

1.1 Purpose of this Manual.............................................................. 1-1

1.2 Related Publications.................................................................. 1-1

1.3 Book Organization..................................................................... 1-2

1.4 Safety ........................................................................................ 1-2

Chapter 2 – Speciﬁcations

2.1 Product Description ................................................................... 2-1

2.2 System Requirements ............................................................... 2-1

2.3 Physical Equipment Specifications............................................ 2-2

2.4 Print Specifications.................................................................... 2-3

2.5 Material Specifications............................................................... 2-7

Chapter 3 - Theory

3.1 Changes From Earlier Models .................................................. 3-1

3.2 Printer Architecture.................................................................... 3-2

3.3 Operating Sequence.................................................................. 3-6

Chapter 4 - Troubleshooting/Diagnostics

4.2 Block Diagrams ........................................................................ 4-2

4.3 Main Controller Board Diagnostics ........................................... 4-4

4.4 Error Codes ............................................................................... 4-9

4.5 Print Samples for Troubleshooting .......................................... 4-12

4.6 Feeding Issues ........................................................................ 4-14

4.7 Printing Issues......................................................................... 4-19

4.8 Display Issues ......................................................................... 4-23

4.9 Miscellaneous Issues .............................................................. 4-23

Table of Contents

iv DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)

Chapter 5 - Removal & Replacement

5.1 List of Procedures...................................................................... 5-1

DA80F (WF81) Parts Removal

5.2 Rear Cover and Keyboard/LCD Display Board ......................... 5-3

5.3 Main Processor Board............................................................... 5-4

5.4 Encoder Assembly .................................................................... 5-6

5.5 Paper Top Sensor Assembly (Emitter) ...................................... 5-9

5.6 Paper Bottom Sensor Assembly (Receiver) .............................. 5-9

5.7 Feeder Sensor Assembly (Emitter and Receiver) ................... 5-10

5.8 Front Bottom Cover Assembly..................................................5-11

5.9 Transport Timing Belt .............................................................. 5-12

5.10 Feed Motor Timing Belt ......................................................... 5-13

5.11 Feed Roller Pulley and Feed Roller Assembly ...................... 5-14

5.12 Feed Motor Assembly and Encoder Harness Assembly........ 5-16

5.13 Transport Motor Assembly..................................................... 5-18

5.14 H-Block Assembly (Media Separators).................................. 5-20

5.15 Print Head Cables and Print Head Boards............................ 5-21

5.16 Entry Idler Roller Arm ............................................................ 5-28

5.17A Feed Deck............................................................................ 5-30

5.17B Front Plate Assembly ........................................................... 5-32

5.18 Transport (Metal Grit) Roller .................................................. 5-34

5.19 Exit (Rubber) Roller............................................................... 5-35

5.20 Power Supply ........................................................................ 5-36

5.21 Print Head Access Door ........................................................ 5-38

DA95F (WF96) Parts Removal

Standard Feeder (WF9S)

5.22 Rear Cover/Side Guides ....................................................... 5-39

5.23 Lower Sensor Receiver Assembly......................................... 5-41

5.24 Feeder Top Sensor (Emitter) Assembly................................. 5-42

5.25 “H Block” Roller (Media Separator) ...................................... 5-43

5.26 Feed Belts and Rollers .......................................................... 5-44

5.27 Motor/Drive Assembly............................................................ 5-46

Table of Contents

DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A) v

Chapter 5 - Removal & Replacement (continued)

DA95F (WF96) Parts Removal

Printer Section

5.28 Printer Top Cover................................................................... 5-48

5.29 Front Cover and Keyboard/LCD Display Board..................... 5-49

5.30 Rear Cover and Processor Board ......................................... 5-51

5.31 Paper Sensor and Sensor Bar............................................... 5-54

5.32 Entry Roller Support Assembly.............................................. 5-55

5.33 Intermediate Idler Rollers Assembly...................................... 5-56

5.34 Idler Roller Support (“Module A”) Assembly .......................... 5-57

5.35 Idler Roller Support (“Module B”) Assembly .......................... 5-58

5.36 Print Head Cables and Print Head Boards............................ 5-59

5.37 Belt Drive Assembly............................................................... 5-67

5.38 Media Belts............................................................................ 5-69

5.39 Encoder Assembly................................................................. 5-71

5.40 Drive Belt/Motor Assembly .................................................... 5-74

5.41 Power Supply ........................................................................ 5-75

Chapter 6 - Adjustments

6.1 List of Adjustments ................................................................... 6-1

Adjustments for All Models

6.2 LCD Display .............................................................................. 6-2

6.3 Feeder Sensor Test and Calibration ......................................... 6-2

DA80F (WF81) Adjustments

6.4 Leveling the Print Head Assembly to Deck (Belts) .................. 6-3

DA95F (WF96) Adjustments

6.5 Leveling the Print Head Assembly to Deck............................... 6-5

6.6 Adjustable Thickness Knob and Eccentric Sprockets................ 6-6

Chapter 7 - Maintenance Procedures

7.1 General Maintenance ................................................................ 7-1

7.2 Specific Maintenance ............................................................... 7-2

Table of Contents

vi DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)

Appendix A – Printer Control Panel Menus and Utilities

A.1 Control Panel Menus for the Printer..........................................A-1

A.2 LCD Control Panel Menu .........................................................A-3

A.2 LCD Main Menu .......................................................................A-4

A.3 LCD Setup Menu ......................................................................A-9

A.4 LCD Service Menu .................................................................A-19

A.5 Setting Factory Defaults (from LCD Menu).............................A-24

A.6 Updating Firmware .................................................................A-26

Appendix B – Printer Communications

B.1 Communication Scenarios ........................................................B-1

B.2 Troubleshooting Tables .............................................................B-4

B.3 Testing Printer Communications Within a Network ...................B-6

Appendix C – Schematics

Main Processor Board for Both Printers...........................................C-2

DA80F (WF81) Printer Block Diagram .............................................C-3

DA95F (WF96) Printer Block Diagram .............................................C-4

Appendix D – Print Head Alignment

D.1 Reason for this Appendix..........................................................D-1

D.2 Print Head Alignment Procedure...............................................D-2

Appendix E – Printing Standards

E.1 USPS® Delivery Point Barcode (DPBC)...................................E-1

E.2 USPS® PLANET Code Barcode...............................................E-3

Index..........................................................................I-1

1 • Introduction

DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A) 1-1

This manual contains instructions for troubleshooting and site repair of DA80F

(WF81) and DA95F (WF96) AddressRight™ fixed head printers. It also includes

complete product specifications and a section on theory for training purposes.

For reference, the table below shows the predecessor fixed head models.

1.1 Purpose of

this Manual

DA80F Operator Guide SV61722

DA80F Parts List SV62033

DA95F Operator Guide SV61749

DA95F Parts List SV62034

DA80/DA95F Hardware Install (US/Canada only) SV61747

DA80/DA95F Hardware Install (outside of US/Canada) SV61774

AddressRight Printer Drivers and

Envelope Designer™ Plus Software Install SV61108

Customer Tutorial for Setting up a DAxxx Series Printer

Using the AddressRight Printer Control Panel Application SV61986

For other information on the printers, refer to these sources:

• Software Control Panel Application (on the host PC) - see the help sys-

tem on the software.

• FAQs document - see the Customer Service website under the product

page for AddressRight™ printers.

• Training - see Enhanced AddressRight™ Fixed Head Printers Self-Direct-

ed Course (GMS-MC-03248) at My Portfolio on the Pitney Bowes intranet.

• Training Job Aids - print the job aids for the software control panel appli-

cation (GMS-MC-03248JA) at My Portfolio on the Pitney Bowes intranet.

1.2 Related

Publications/

Information

New

Marketing

Model

New

PCN Printing

Capability Speed Predecessor

Marketing

Model

Predecessor

PCN

DA80F WF81 Black and

spot color

Up to 22,000

#10 or DL

envelopes

per hour

DA400 W400

DA95F WF96 Black and

spot color

Up to 30,000

#10 or DL

envelopes

per hour

DA950 W803

1-2 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)

1 • Introduction

Personal Safety

Follow these precautions for your own safety:

• Treat every circuit like a gun that may be loaded. It may not be “live,” but be

sure. Check with a neon tester or voltmeter, or simply unplug the machine.

• Know how to turn off power in the work area and get help in an emergency.

• Don’t underestimate the danger of shock: 1 mA (1/1000 amp) is uncom-

fortable; 5 mA is dangerous —you may jump back and be injured; 12 mA

causes hand muscles to contract, so you cannot free yourself; 24 mA has

proven fatal; and 100 mA (1/10 amp) is likely to be fatal.

Familiarize yourself with proper procedures and methods before you install,

operate or repair the equipment to avoid personal injury or damage to the

equipment. If you train service people or equipment operators, it is important to

explain safety precautions to your students and encourage safety awareness.

1.4 Safety Warning messages appear throughout this manual to alert you to potentially

hazardous conditions. Two designations indicate their relative seriousness:

WARNING! Calls attention to improper practices that

could result in a potentially serious, even lethal injury to

you or the customer.

CAUTION! Calls attention to practices that could

cause minor injury to you or a customer or that could

damage equipment or material.

Chapter 1: Introductory and safety information

Chapter 2: Product specifications

Chapter 3: Theory of operation

Chapter 4: Troubleshooting and Diagnostics

Chapter 5: Removal and replacement procedures

Chapter 5: Adjustment procedures

Chapter 7: Maintenance procedures

Appendix A: Printer Control Panel Menus

Appendix B: Printer Communications

Appendix C: Schematics/Diagrams

Appendix D: Print Head Alignment

Appendix E: Printing Standards

1.3 Book

Organization

DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A) 1-3

Introduction • 1

Personal Safety (continued)

• Don’t work on equipment under power unless it’s absolutely necessary.

If you must, use extreme caution. Don’t grasp two sides of a live circuit

at the same time—use one hand when reaching into a circuit, touching

a grounded case or chassis with that wrist or elbow if possible. This pre-

vents current from passing through vital organs. Observe this rule when

connecting or disconnecting plugs or leads, or making any adjustments

on a live circuit.

• Use the right tools for the job. A tool which slips can cause a short—or a

shock. Don’t reach into a circuit with metal tools, or while wearing rings or

a watch. Even in low voltage circuits, a metal object can short circuit two

terminals. When working on live circuits, use tools with insulated handles

and try to keep your tool hand grounded.

• Don’t bypass safety devices, particularly fuses. Three-wire outlets (120

Vac) are designed to ground equipment to make it safe. If a hot wire

shorts to a grounded frame, the only result is an open fuse. If a hot wire

shorts to an ungrounded frame, the frame itself becomes hot and poten-

tially dangerous. A fuse is a weak link in a circuit, designed to break down

before anything else does. The maximum safe current in a circuit is de-

termined by the designers. Too large a fuse can pass excessive current,

damaging expensive equipment.

• For electrical fires, use Type C, BC or ABC extinguishers only. Don’t use

soda acid or other liquid stream extinguishers. They will damage elec-

trical equipment and present a shock hazard to the user.

• Digital equipment can be easily damaged or destroyed by static charges.

Microprocessors and other integrated circuits contain tiny transistors not

much more than a millionth of an inch across, which operate at 5 to 12

volts.

• Be extremely careful when lifting heavy equipment. Follow the guidelines

below:

a. Squat to lift and lower. DO NOT bend at the waist.

b. Keep your low back bowed in while bending over.

c. Keep the weight as close to you as possible.

d. Bow your back in and raise up with your head first.

e. If you must turn, turn with your feet, not your body.

f. Never jerk or twist!

g. Put the weight down by keeping your low back bowed in.

h. Keep your feet apart, staggered if possible.

i. Wear shoes with non-slip soles.

j. Get help if you need it.

1.4 Safety

1-4 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)

1 • Introduction

Electrostatic Discharge (ESD) Procedures

Follow these guidelines to protect sensitive equipment from static damage:

• Always use a wrist grounding strap and anti-static mat when working on

equipment sensitive to electrostatic discharge. These items are furnished

in the ESD Field Service Kit, L-8351.

• Ground yourself before reaching into the equipment, or touching any

circuit board or other electrical component. Just touching a doorknob or

metal workbench may be enough, but the best guarantee is to turn the

machine off but leave it plugged in, and ground yourself on the chassis,

which is grounded through the three-wire power cord.

• Be careful of rugs—even a few steps can recharge you. Re-ground your-

self whenever you’ve walked away and returned to the machine. Rugs

are a major source of static buildup in the body.

• Take greater precautions as the objects you handle get smaller. A board

in the machine is better protected than one that is not plugged in; a chip

on a board is better protected than one in your hand.

• Stay away from metal conductors. The plastic and resin that chips and

boards are made of are much better insulators than metal. It’s most im-

portant to keep your hands away from any metal which contacts the data.

In particular, this means the long connector along the bottom of each

board, and the pins coming out of the chips. These signal and data lines

are directly connected to the fragile inner circuits of the chips. When han-

dling a board, try not to touch the connector; when handling a chip, try

not to touch the pins.

1.4 Safety

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