Pitney Bowes DM200i Series Service Manual & Parts List

DM100i/DM200i series

Mailing System

Service Manual & Parts List

FORM SDT345A (8-07)

IMPORTANT:

Model and feature availability varies by country. Contact your machine supplier for more information.

This guide covers all models and features. Inclusion within this guide does not guarantee availability of a particular model or feature within your country.

The title, copyright and all other proprietary rights in this document are vested in Pitney Bowes Limited and no part of it may be reproduced in any form without the written permission of Pitney Bowes Limited.

The document is for the exclusive use of the person to whom it is issued; its contents are confidential and must not be disclosed to any third party or used for any purpose other than in the proper conduct of Pitney Bowes Limited's business and it must be returned to Pitney

Bowes Limited immediately upon the person ceasing to be associated with Pitney Bowes Limited.

© Pitney Bowes Limited, 2007

Service Manual

Page

SecTION 1

Introduction

1.1 - Purpose ............................................................................................ 1-1

1.2 - Equipment Covered .......................................................................... 1-1

1.3 - Contents ........................................................................................... 1-1

1.4 - Safety Summary ............................................................................... 1-1

1.5 - Equipment Safety ............................................................................. 1-2

SecTION 2

Specifications

2.1 - Material Specification ........................................................................ 2-1

2.2 - Machine Specification ....................................................................... 2-2

SecTION 3

Removal & Replacement

3.1 - External Covers ................................................................................ 3-1

3.2 - Carriage Unit Related ....................................................................... 3-4

3.3 - Purge Unit Related ............................................................................ 3-9

3.4 - Lower Delivery Unit Related .............................................................. 3-12

3.5 - PCBs ................................................................................................. 3-18

SecTION 4

Troubleshooting

4.1 - Introduction ....................................................................................... 4-1

4.2 - Troubleshooting Tables ..................................................................... 4-1

Parts List

SecTION 5

Parts List

........................................................................................................... 5-1

SDT345A DM100i Series Service Manual & Parts List i

• Contents ii SDT345A DM100i Series Service Manual & Parts List

1.1 PURPOSe

This document provides the information necessary to support the installation and site repair of the

DM100i/DM200i Series Digital Mailing System.

1.2 eQUIPMeNT cOVeReD

This manual applies to the DM100i/DM200i Series and the kits required for digital mailing system operation.

1.3 cONTeNTS

This manual is organised as follows:

● Section 1 – Introduces the manual

● Section 2 – Lists material and equipment specifications

● Section 3 – Presents removal and replacement procedures

● Section 4 – Offers Troubleshooting advice.

● Section 5 – Provides a full parts list.

1.4 SAFeTY SUMMARY

Warning messages are used throughout this manual to alert you to potentially hazardous conditions.

These warnings are explained below.

● WARNING — calls attention to improper practices that could cause injury.

● cAUTION — calls attention to improper practices that could damage the equipment or the material being run.

● IMPORTANT — calls attention to practices that could adversely affect equipment operation, if instructions are not followed exactly.

You must familiarise yourself with proper procedures and methods before you install, operate or service the equipment to avoid personal injury or damage to the equipment. If you are responsible for training service personnel or equipment operators, it is incumbent on you to explain safety precautions to your students and encourage safety awareness.

The following is a list of general precautions which cannot be over emphasised:

● HIGH VOLTAGE is present at certain points in the equipment. INJURY or DEATH could result if you fail to observe safety precautions.

● Know how to turn off power in the work area and how to summon help in case of emergency.

● Do not work on equipment under power unless absolutely necessary.

● When working on a live circuit, use extreme caution. Don’t grasp two sides of a live circuit at the same time.

● Always use the right tools for the job.

● Treat every circuit like a gun which may be loaded. It may not be “live”, but be sure. Check with a neon tester, a voltmeter, or simply unplug the machine.

SDT345A DM100i/DM200i Series Service Manual & Parts List 1-1

1 • Introduction

● Use one hand when reaching into a circuit. By keeping one hand free, lethal current is less likely to pass through vital organs. Observe this rule when connecting or disconnecting plugs or leads, and when making any adjustments on a live circuit. Don’t underestimate the danger of shock: 1mA

(1/1000 ampere) is uncomfortable; 5 mA (1/200 ampere) is dangerous - the victim may jump back and be injured; 12 mA (1/83 ampere) causes hand muscles to contract - the victim cannot free himself; 24 mA (1/40 ampere) has proven fatal; and 100 mA (1/10 ampere) is likely to be fatal.

● 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.

● Don’t bypass safety devices. Three-wire outlets (220/240 VAC) are designed to ground equipment to make it safe. If a live wire shorts to a grounded frame, the only result is an open fuse. If a live wire shorts to an ungrounded frame, the frame itself becomes hot and potentially 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 determined by the designers. Too large a fuse can pass excessive current, damaging expensive equipment. Interlock switches are designed to remove power from a circuit when an access door, cover or panel is opened. When such a switch is “cheated” or otherwise disabled, a safety device has been bypassed. If you bypass an interlock for service or diagnostic purposes, use extreme caution.

● If you use air pressure to clean a machine, use low pressure (30 psi or less) and use eye protection (goggles or face masks).

● When using solvents or cleaning fluids, make sure ventilation is adequate.

1.5 eQUIPMeNT SAFeTY

Just by walking around, you yourself may carry a threat to the equipment, in the form of a high voltage electrostatic charge. Your body acts as a giant capacitor which can store large amounts of electricity.

Walking across a rug can charge you with several thousand volts, which can discharge in a spark up to an inch long.

Digital equipment can be easily damaged or destroyed by static charges. Microprocessors and other

ICs contain tiny transistors not much more than a millionth of an inch across, which operate at 5 to

12 volts. You don’t have to see a spark to ruin an IC — 50 volts is enough. Follow these guidelines to protect sensitive equipment from static damage:

● 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. If you have access to one, bring a grounding strap and use it.

● Be careful of rugs — even a few steps can recharge you. Re-ground yourself whenever you’ve walked away and returned to the machine. Rugs are a major source of static buildup in the body.

1-2 SDT345A DM100i/DM200i Series Service Manual & Parts List

Introduction • 1

WARNING!

Always be sure the equipment is unplugged before you make any attempt to perform the maintenance outlined in this manual. If you must work on a

"live" machine, note that line potential is present at the power panel and the motherboard.

CAUTION: DO NOT attempt to adjust key timing parameters in the service menu unless you have been trained and thoroughly understand what you're doing.

Otherwise you could damage the equipment.

● Take greater precautions as the objects you handle get smaller. A board in the machine is better protected than one which 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 important 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 handling a board, try not to touch the connector; when handling a chip, try not to touch the pins.


1 • Introduction


2.1 MATeRIAL SPecIFIcATIONS

Material Specifications

Material (see figure below)

Minimum Size : 127 mm x 76 mm

Maximum Size: 381 x 330 mm

Minimum Flap Depth: 22 mm

Maximum Flap Depth: 76 mm

Minimum Thickness: 0.18 mm

Maximum Thickness: 9.5 mm

Maximum Stack Height for Mail: 60 mm

IMPORTANT: For best results, always make sure your material conforms to our published specifications.

381mm

76mm

Maximum

330mm

127mm

76mm

Minimum

22mm


2 • Specifications

2.2 MAchINe SPecIFIcATIONS

Size of Base Model:

215mm H x 345mm W x 400mm D

Size of Base Model with Scale:


Size of Base Model with Scale and Moistener:


Stacker:

The stacker adds 265mm to the width of the system.

Weight:

6.8Kg, approximate.

Power Requirements:

100-240 VAC, 50/60Hz. 1.0A

Communication Ports:

1 USB (B); 1 RJ-11.

Operating Temperature:

4°C to 42°C.

LCD Display: 4 Lines, 20 characters long.

Throughput: Up to 30 letters per minute with no moistener; somewhat less with optional moistener.

Actual throughput will vary depedning on the material used, machine condition, use of moistener, and the skill of the operator.

Print Resolution: 600 x 300 dpi

Print Image Area: at least 25.4mm x 170mm

Ink Cartridge Life: 2,500 imprints or 22 letters per day, 5 days a week for 6 months.

Tape Sheets: Self-adhesive type, dual tape sheets.

Internal Ad Storage; up to 20.

Departmental Accounting: Number of accounts available based on the amount purchased and model.

2-2

compliance It is certified that the digital mailing systen machine complies with the requirements of the Low Voltage Directive 73/23/EEC and the EMC

Directive 89/336/EEC. The product was tested in a typical configuration.

For a formal Declaration of Conformity please contact Compliance

Engineering on +44 (0)1279 426731.

WARNING: This is a class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures.

SDT345A DM100i/DM200i Series Service Manual & Parts List

3.0 external covers

3.0.0 Removing the Upper Cover Unit

1) Open the open/closed cover [1].

[1]

2) Remove the 2 screws [1].

[1]

3) Remove the screw [1], and detach the upper cover unit [2].

[2]

[1]

4) Free the harness [2] from the 2 harness guides

[1]. Disconnect the connector [3] on the left side of the main body. Remove the upper cover unit [4].

[4]

[3]

[2]


[1]

3-1

3 • Removal & Replacement

3.0.1 Removing the Control Panel Unit

1) Remove the upper cover unit. (See A-1 Removing

the Upper Cover Unit)

2) Remove the 4 screws [1].

[1]

3) Remove the control panel unit [1].

[1]


3.0.2 Removing the Lower Cover Unit

1) Remove the upper cover unit. (See A-1 Removing the Upper Cover Unit)

[1]

2) Pull out the lever [1].


3) Remove the 2 screws [1] on the left side of the main body.

[1]

4) Remove the 2 screws [1] on the right side of the main body, and detach the lower cover unit [2].

[1]

[2]



3.1 carriage Unit Related

3.1.0 Removing the Carriage Unit

Carriage unit consists of the carriage, the guide rail of the carriage and the carriage motor.

1) Remove the upper cover unit. (See A-1

Removing the Upper Cover Unit)

2) Remove the lower cover unit. (See A-3

Removing the Lower Cover Unit)

3) Turn the gear [1] clockwise with using a screwdriver, to uncap the print head. The cap can be seen from the window [2].

[2]

[1] caution-

Never move the carriage being capped to prevent the print head and the cap from damage.

4) Open the ink tank exchange cover, and remove the ink tank.

[1]

5) Remove the print head [1].

[1]


6) Disconnect the connector [1]. Remove the screw [2] and detach the interface connector unit [3].

[2]

[3]

[1]


7) Remove the screw [1]. Unlock the flexible cable connector and detach the flexible cable

[2].

[1]

[2]

8) Remove the screw [1].

[1]

9) Disconnect the connector [1], and remove the screw [2].

[2]

[1]



10) Slide the carriage [1] to the front, then move the carriage unit [2] to the rear side, and remove the carriage unit [2].

[2]

[1]

3.1.1 Removing the Carriage Drive Motor

1) Remove the carriage unit. (See B-1

Removing the Carriage Unit)

2) Remove the screw [1] and detach the carriage drive motor [2].

[2]

[1]


3.1.2 Removing the Head Holder Unit

1) Remove the carriage drive motor. (See

B-2 Removing the Carriage Drive Motor)

2) Remove the screw [1], and detach the carriage drive rail [2].

[2]

[1]


3) Unlock the hook [1] of the flexible cable cover.

[1]

4) Slide the flexible cable cover [1] to the left side, and detach it. Remove the head holder unit [2].

[1]

[2] caution

Do not loosen the tensioner screw [1] of tension adjustment for the carriage drive belt must be made.

[1]



3.1.3 Adjustment at installation of the carriage drive belt

The tension adjustment of the belt is necessary after the carriage drive belt is exchanged.

1) Loosen the screw [1].

[1]

2) Adjust belt tension at the hook [1] so that the tension falls in the tolerance.

Tolerance: 1 kg±10%

[1]


3.2 Purge Unit Related

3.2.0 Removing the Waste Ink Tank Unit

Waste ink tank unit consists of the ink tank case and the ink absorption sheet.

[1]

1) Remove the lower cover unit. (See A-3

Removing the Lower Cover Unit)

2) Remove the waste ink tank unit.


[1]

3.2.1 Removing the Purge Unit

1) Remove the carriage unit. (See B-1 Removing the Carriage Unit)

2) Disconnect the 2 connectors [1], and remove the

2 screws [2].

[2]

3) Remove the purge unit [1].

[1] caution

Never touch the cap and the wiper blade.



3.2.2 Removing the sensor PCB (1)

1) Remove the purge unit. (See C-2 Removing the

Purge Unit)

[1]

2) Remove the 2 hooks, and detach the cover [1].

3) Remove the 2 screws [1], connector [2], and detach the sensor PCB (1) [3].

[1]

[2]

[3]


3.2.3 Removing the Purge Motor Unit

1) Remove the purge unit. (See C-2 Removing the

Purge Unit)

[1]

2) Remove the 2 hooks, and detach the cover [1].


3) Unlock the hook [1], and remove the 2 gear [2].

4) Disconnect the connector [3].

[3]

[1]

[2]

5) Remove the 2 screws [1], and detach the purge motor unit [2].

[2]

[1]



3.3 Lower Delivery Unit Related

3.3.0 Removing the Lower Delivery Unit


2) Remove the lower cover unit. (See A-3 Removing the Lower Cover Unit) caution

Do a pressure release of the delivery unit prior to removing the lower delivery unit.

3) Remove the screw [1] on the left side of the main body.

[1]

4) Remove the 2 screws [1], and detach the tray [2].

[2]

[1]

5) Remove the screw [1] on the left side of the main body.

[1]


6) Remove the screw [1] on the right side of the main body, and detach the lower delivery unit [2].

[2]


[1]

3.4 Upper delivery Unit Related

3.4.0 Removing the Encoder Sensor



[1]

2) Remove the connector [1] and screw [2], and detach the encoder sensor.

[3]

[2]



3.4.1 Removing the Delivery Motor

1) Remove the purge unit. (C-2 Removing the purge unit)

2) Disconnect the connector [1], and remove the harness [2] from the 5 harness guides [3].

[1]

[2]

3) Remove the 2 screws [1] from rear frame.

[1]

4) Remove the delivery motor [1].

[1]

[3]

3.4.2 Caution at the delivery motor installation

At the delivery motor installation, locate the motor so that the harness come to the position as shown.



3.4.3 Removing the delivery belt

1) Remove the upper cover unit. (A-1 Removing the

Upper Cover Unit) caution

Do a pressure release of the delivery unit prior to removing the delivery belt.

2) Loosen the screw [1] temporarily and fix the screw [1] again while compressing the spring [2] to lower the tension. Remove the delivery belt [3].

[1]

[2]

[3]

3.4.4 Removing the Upper Delivery Unit

1) Remove the carriage unit. (See B-1 Removing the

Carriage Unit)

2) Remove the lower delivery unit. (See D-1 Removing the Lower Delivery Unit)

3) Remove the delivery belt. (See E-4 Removing the delivery belt)

4) Remove the screw [1], belt [2], and gear [3].

[2]

[1]

[3]



5) Remove the rail [1] and bushing [2].

[2]

[1]

6) Remove the 4 screws [1], and detach the upper delivery unit [2].

[2]

[1]


3.4.5 Removing the encoder

1) Remove the upper delivery unit. (See E-5

Removing the Upper Delivery Unit)

[1]

2) Remove the screw [1], and detach the encoder cover [2].

[2]

3 • Removal & Replacement caution holding the encoder, with hand, hold it as shown.

[2]

3.4.6 Removing the Sensor PCB (2)

1) Remove the encoder. (See E-6 Removing the encoder)

2) Remove the 2 screws [1] and connector [2], and detach the sensor PCB (2) [3].

[2]

[3]


[1]

[1]

3-17


3.5 PcBs

3.5.0 Removing the Main PCB


[1]

[1]

2) Disconnect the all connector [1] and flexible cable

[2] on the main PCB.

[4]

[4]

3) Remove the 3 screws [3] on the main PCB, and detach the main PCB [4].

[2]

[2] caution

Unlock the connector when removing flexible cable.

caution

Dispose of the lithium battery according to local regulations.

The lithium battery for the main

PcB is a non-replaceable part.

3.5.1 Removing the Modular PCB

1) Remove the main PCB. (See F-1 Removing the

Main PCB)

2) Remove the connector [1] and the 3 screws [2] and detach the modular PCB [3].

[2]

[2]

[1]

[1]

[3]

[3]

[3]

[3]


3.5.2 Removing the DC Power Supply Unit



2) Disconnect the 2 connectors [1], and remove the harness from the harness guide [2].

[2]

[4]

3) Remove the screw [3], and detach the open/ closed cover sensor [4].

[3]


[1]

4) Disconnect the 2 connectors [1].

[1]

5) Remove the screw [1].

[1]

6) Remove the harness from the harness guide [1].

7) Remove the screw [2], and detach the DC power supply unit [3].

[3]

[1]

[2]




4.0 Introduction

This chapter explains how to troubleshoot the DM100i and DM200i. It includes troubleshooting charts and a list of error codes and their meanings.

4.0.1 General Troubleshooting

Before troubleshooting the equipment, check that the customer's material falls within the specifications published in Chapter 2 of this manual. You can often trace frequent feed failures to substandard or out-of-spec material or to improper feeding techniques on the part of the operator.

If the problem involves poor print quality, run a test print (Option > Scroll Down > Maintenance > Printer

Maintenance Mode > Test Print) and evaluate the sample. If the test print is not acceptable, select No,

Clean Nozzle when prompted. This action automatically runs the manual maintenance functions. Repeat the maintenance procedure if necessary.

4.0.2 Error Messages

The system can display a number of error messages that describe fault conditions. Table 4-10 is a general summary of these messages arranged by their most significant digits. Tables 4-11 onwards list many error codes.

4.2 Troubleshooting Tables

Tables 4-1 through 4-9 present troubleshooting information for the following problems:

• Power On and Initialization Faults

• Display Faults

• Transport Faults

• Tape Feeder Faults

• Printing Faults

• Carriage Movement Faults

• Moistener Faults

• Postage By Phone Errors

• Modem Faults

• Integrated Scale Faults

SDT345A DM100i/DM200i Service Manual & Parts List 4-1

4 • Troubleshooting

Table 4-1 Power ON and Initialization Faults

errors

Mailing machine is connected to power, but control panel

LeD is off, no initialization, no display, no printer sounds. code 010e displays.

“Printer Fault” error displays. error 2447.

“System Fault” error displays. error 2554.

1/2 “Jam Lever

Open” and 2/2

“clear Transport” errors display.

checkpoints

Does the cord show obvious signs of wear?

Does another cord work?

Is the power cord connected to a functioning wall outlet?

Defective power supply board. System dead.

System starts to initialize, but hangs.

LED is green. No printer noise (no printer initialization). Screen stuck on “Initializing...

Please Wait...”

An error occurred during printer initialization process. This is a CM/PM initialization timeout.

Does Error 2447 display?

Does Error 2554 display? 2304?

If these errors display when the jam lever is closed and the transport is clear, the sensor board may be suspect.

Possible causes/Solutions

Replace the power cord.

Check wall outlet. Is it switch-controlled? If machine is connected to a power strip, try connecting it to a known good wall outlet.

Check for 27V (to feeder, transport motor, and print head) and 5V (to control panel, main logic). Check wiring to an connection at Main

Logic Board, J9.

Verify that all interlocks are closed. Power supply. Check wiring from PS board to Main

Logic Board, J14.

• If this occurs during install, check that all shipping tape has been removed from unit.

• Unplug power cord from unit and then wall outlet. Wait three minutes. Plug cord into unit and then into machine. If this problem occurs every time machine is power cycled, replace it.

• Check that ink cartridge cover is closed.

The system failed to detect the print carriage.

Check ribbon cable from print head to J13 on

Main Logic Board. Problem could be caused by bad connection, ribbon cable, print head controller board (sealed in carriage assembly) and print head.

The system failed to detect the Postal Security

Device (PSD). Communications with PSD failed. Is PSD present? Check that it is properly seated and making full contact with board.

2304 is a communication timeout error.

Check sensor board and wiring to Main Logic

Board, J8.

4-2 SDT345A DM100i/DM200i Service Manual & Parts List


Table 4-2 Keyboard and Display Faults

Fault

Keyboard failure. Does not respond.

No display.

checkpoints

Wiring from keyboard to J4. Keyboard PCB.

Machine may be in sleep mode. Is front panel

LED orange?

Check display contrast.

Machine not getting power.


Poor connection at keyboard, wiring and connection at Main Logic Board, J4.

Press any key to wake unit.

Adjust display contrast as required.

Power cord not plugged in. Power cord plugged into a switched or defective outlet. Try another wall outlet. If unit is plugged into a power strip, move the power cord to a functioning wall outlet.

Check connector J4.

Display does not change.

No display, front panel LED off, but print head initializes at start up.

See Table 4-1 for power ON an initialization faults.

Meter appears to be “stuck” on the same display for an extended period of time.

Power cycle the meter to reboot and start over.



Table 4-3 Mailing Machine Transport Faults

Fault

Operator error.

Interlocks.

Transport fails to drive.

checkpoints

Operator may be feeding piece improperly.

Are cartridge access cover and lower transport closed?

Transport drive motor and drive components.

Drive belts damaged or improperly tensioned.


Instruct operator to position envelope top edge against rear wall and slide it to right.

An error message should display if either interlock is open.

Test using service diagnostics. Also check harness and connection at J7.

Check drive belts and tensioners.

Transport fails to drive,

(continued).

Frequent jams.

Frequent skews.

No printing occurs.

Drive shaft fails to turn. Drive shaft is binding.

Transport drive belt.

Lower transport problems.

Debris in transport; envelope thickness out of spec.

Operator error.

Envelope blank, no errors.

Check pulleys. Make sure they are securely mounted on shaft.

Check belt for proper tracking. Check for wear, glazing, cracks, etc.

Make sure lower transport locks in operating position and that idlers contact transport drive belt. Check that all idlers are correctly positioned and turn freely.

Check transport, clean as required. Maximum envelope thickness is 9.5mm.

Instruct operator to make sure top edge of mail piece is against registration wall. Cusomer should not hold on to mail as he or she feeds it onto deck. If oversized mail piece, use a tape strip.

Check ink cartridge. Perform purge. Clean electrical connections; check electrical connections.



Table 4-4 Printing Faults

errors

No print out of box.

checkpoints

In some cases, the print head may dry out or be cold from shipment. This could result in a no print condition. Allow the system to warm up to room temperature. Follow steps at right.

Possible cause/Solution

1. Complete install.

2. After install is complete, remove ink cartridge and print head.

3. Make sure tape has been removed from bottom of print head and tab has been removed from ink cartridge,

4. Check that ribbon cable from carriage assembly to J13 is intact and properly connected.

5. Clean the gold connectors on the side of the print head with a pencil eraser.

6. Install the print head and ink cartridge.

7. Check the capping station. Clean if necessary.

8. Test print quality. Test and purge procedure is available through the user

(OPTIONS). From the user menu, press

OPTIONS > Scroll down > Advanced

Features > Maintenance Mode > Printer

Maintenance > Test Print. See illustration below.

9. If print quality is poor, perform up to three

“C” purges. Then perform a “D” purge.

Poor print quality: gaps and voids.

Purge may be required. Test and purge procedure is available through the user

(OPTIONS). From the user menu, press

OPTIONS > Scroll down > Advanced Features

> Maintenance Mode > Printer Maintenance >

Test Print.

NOTe: For a poor print issue that will not clear with a basic purging, perform the printhead replacement procedure. With the system running, open the print head/ink access cover. Select “Replace Print Head.”

Physically remove the printhead and reinstall it following the prompts.

GOOD BAD

Figure 4-1 Print Test Patterns

If the test pattern shows gaps or voids, purge the printer nozzles and retest. If little or no improvement is noted, you may repeat the purge up to five times total.



Table 4-4 Printing Faults (continued)

errors

Poor print from used ink cartridge.

Print is not clean and crisp; smearing or spotting evident.

Ink supply is okay.

checkpoints

Follow steps at right.

Wiper blade. Also check the “wiper.” It is easily replaceable.

Does a purge correct the problem?

Is the carriage moving normally so that wiping occurs?

Is the printhead harness properly connected at

J13?


Remove the printhead and check for bent pins.

Pins are normally angled downward.

Make sure printhead is correctly installed.

Check printhead harness and connection at

J13.

If purges fail to correct the problem, and the ink cartridge is not empty, replace the printhead.

If this fails to correct the problem, there may be a problem with the print head carriage board.

This requires replacement of the print head carriage assembly.

Check the wiper blade for excess ink accumulation. Clean as required. Replace wiper wiper if necessary.

If needed, purge and run a test print.

Check carriage movement and correct any problems. See table 4-5

Make sure it is locked in position.

No print, red or partial print.

Partial, streaked or Incomplete print.

customer complains that ink usage is high.

Possible print head controller (PHC) failure.

Wiper and/or capping station may be contaminated with excess ink. Purge may be required.

Ink yield is based on usage. Higher usage prolongs cartridge life because more ink is used during maintenance than printing.

Clean wiper and capping station. Perform a “C” purge, then a “D” purge.

Is machine in seal-only mode? This mode disables printing.

Is the customer performing manual purges?

This increases ink consumpton.

4-6

Check for bent pins

How often does the customer use the meter?

When was the ink cartridge installed?

Is the customer printing ads? This increases ink usage.

Is the customer printing reports? This increases ink usage.

Make sure tape is off print cartridge bottom.

Check for bent pins. These are behind print head (see figure) and are angled downward.

Figure 4-2 contact Pins

SDT345A DM100i/DM200i Service Manual & Parts List

Table 4-4 Printing Faults (continued)

errors

Poor print with new ink cartridge.

checkpoints

Purge.

Print head/ink tank not detected.



Perform a “B” purge and run a test print.

Normally two such purges will result in a clear, crisp print. If not, you can try up to three more purges. If these fail, the print head, print head ribbon cable and connection at J127 are suspect. See instructions for Poor print from used ink cartridge.

1. Reinstall print head and ink cartridge.

Check for bent pins when you do this.

Make sure cap was taken off printhead and tape removed from cartridge. Check that print head is snapped into position.

2. Reboot.

3. Check PH ribbon cable and connection at

J13.

4. Print head may be suspect.



Table 4-5 Print carriage Faults

errors

Print carriage fails to move from home to print position.

NOTe: It is normal for the print head to move back to the home position if an envelope or tape is not sensed by PS1 for 15 seconds.

error 2443.

checkpoints Possible cause/Solution

PS1 fails to sense envelope or tape lead edge.

Check for debris in transport path.

Carriage drive belt.

Carriage drive rails.

Inspect belt and pulleys. Check that belt is centered on pulleys and fully engages loop on carriage.

Check that carriage assembly is not binding on rails. Assembly should move freely.

Purge motor.

If the purge motor fails to turn clockwise with the carriage assembly in the home position, the printhead lock and cap will remain up, preventing movement of the carriage. Check the harnesses from the purge motor to connectors J5 and J9 on the Main Logic Board.

And grinding noise.

error 2442.

Printer Fault.

Indicates carriage motor failure or wiring problem. System locks when error message is cleared. See Carriage drive stepper motor above.

Possible problem with cap motor or sensor located in purge unit. System may lock when error is cleared. Check wiring to Main Logic

Board, J5. In addition, check purge motor and wiring to Main Logic Board, J9.



Table 4-6 Moistener Faults

Problem envelopes don’t seal.

Possible cause

Incorrect feeding.

Low sealant level.

Dry moistener brush.

Dirty moistener brush.

Worn moistener brush.

Table 4-7 Miscellaneous Faults

Problems

Lock code customer forgot meter lock code.

checkpoints

“Ink Tank Access cover Open”.

Access cover.

System is noisy.

Lubrication may be required.

Solution

Check that operator is sliding envelope flap under blue edge of feed deck. If this is not done, moistener can’t wet flap.

Check sight glass on moistener tank. If level is low, add E-Z

Seal® until it reaches bottom of fill hole.

Try wetting moistener brush. If brush drys out quickly, replace moistener wick.

Remove brush, clean in plain water and rinse thoroughly.

Replace moistener brush.

Possible cause/Solutions

Go to Enter Lock code screen. Type in 6946-

Refill. This will take you to the service mode.

Press Clear. This takes you to the main menu.

Lock Code will override Supervisor Code.

Close access cover. If this doesn’t correct problem, check sensor flag. Sensor must be blocked when cover is closed. If flag is okay, check wiring and connection at Main Logic

Board, J11.

Use teflon/silicone grease on feeder gear shafts if there is noise. Also use on white tension idler rollers if they make a high squealing noise.



Table 4-8 Modem/connection Faults

Problem

Machine fails to connect to

Postage By

Phone Data center: No dial tone.

Possible cause

System not connected to working analog phone line.

Solution

1. Make sure the phone cord is firmly connected to a single line analog phone jack. The term analog phone line refers to a RJ11C or RJ11W compatible (single line) telephone wall plug typically used for a residential phone, analog dial-up computer modem or facsimile

(fax) machine.

2. Insure the dialing prefix is set properly if needed.

3. Verify whether a delay (pause) is required in the dialing sequence. For example, a pause may be required after the prefix.

4. Verify the correct PB Phone No is entered-

0845 912 2401.

5. There may be a problem with the meter serial number not being recognized by PBP. Are there any error codes displayed? Check the Error Log before and after attempting the connection.

6. There may be telephone line noise or attenuation causing the line to drop. Trying a different phone number may help.

7. Connect an analog telephone to the line and verify that you can dial out and hear clearly on the line.

8. If a line splitter is used, try removing it and connect directly to the wall jack.

9. If the customer is using DSL, try connecting through the DSL Analog/Digital Filter while no one is on the internet.

10. Could not connect because of V.42 connect time out.

This can happen with satellite transmissions. Slowing down the modem often resolves this. Please see

changing the Modem Speed, next page.



Table 4-8 Modem/connection Faults (continued)

Problem

Machine fails to connect tp

Postage By

Phone Data center: No dial tone.

Possible cause changing the modem speed:

Solution

Version 8.60 Meters are built with a default Modem

Initialization String setting, as follows:

ATE0&K0M1X4W2S9=50S7=90^M

Using the following Key sequence will take you to the screen which allows you to edit this string:

Options > Connect to Data Centre > Phone Parameters >

Modem Parameters

Select Modem String

Select Continue

Select Edit Options

Then, using the Move Cursor Left and Move Cursor Right soft Keys, edit the string so it looks like:

ATE0&K0M1X4W2S9=50S7=90+MS=V34^M

Add the ‘+MS=V34’ to the string; it MUST be placed before the ‘^M’

NOTE: Special characters like + = ^ can be found on the

QWERTY Keyboard. For + use G, for = use A, for ^ use

B. Version 11.14 uses the new string. If problems are still encountered try

V32 14400 baud

V22 2400 baud

Once the string looks correct then:

Modem setup incorrect.

Faulty modem.

Select OK

Select Accept

Select Done

Check that modem setup is correct. Go to OPTIONS and scroll to CONNECT-DATA CENTRE. Is tone/pulse setting correct? Is a dial prefix required to get an outside line? Is

PbP number correct? Other modem parameters OK?

Check that modem is properly seated on main logic board and that connection between J2 on modem board and J21 on main logic board is sound.



Table 4-9 Integrated Scale Faults

Problem

Scale problems at time of install.

Possible cause

The scale line is not showing or an error code (e.g., 1103, 11F6) displays

Try steps at right.

Solution

Put in for a download.

1. Try uploads and downloads.

2. Push down hard on the scale, then reboot.

3. Remove the rubber feet on the scale, push down on scale and reboot.

4. Check that RS232 connector and pins are okay.

5. Check harness from DB-9 connector to J107 on Main

Logic (Controller).

6. If this fails, place in the Print Head Queue.

7. Check DLA. If the scale feature dowloaded, replace the scale.

8. If no scale feature downloaded, place in the print head queue.

Scale problems after install.

Weight over capacity.

Rate manager not initialized.

Scale does not function; unable to rate mail on scale.

Auto scale function does not work.

If the scale has been working and the scale line shows but nothing else, or the scale line shows with g, but no zeroes, try steps at right.

User attempted to weight an item that exceeds the maximum capacity of the platform they ordered.

Check the order to verify the weight capacity was ordered.

Is scale seated properly?

1. Push down hard on the scale, then reboot.

2. Remove the rubber feet on the scale, push down on scale and reboot.

3. Check that RS232 connector and pins are okay.

4. Check harness from DB-9 connector to J3 on Main

Logic (Controller).

5. If this fails, replace the scale but DO NOT put into Print

Head queue.

See error 1103 if this is not the case. If these steps don’t work, follow the local process to have the DLA reset.

Advise the customer to perform a download in 24 hours.

Follow the local process to have the DLA reset. Advise the customer to perform a download in 24 hours.

Reseat scale. Is serial port set to “Attached Scale?” Check serial port wiring to Main Logic Board, J3. Is rating feature enabled?

Auto scale may be turned off. Scale not set up properly.

Enter menu and make sure auto scale function is ON.



Error

2003 and 2004

220C

24A4 or 24A5

2442

DE06 or DE14 Attempt to connect to Postage By Phone was unsuccessful, Check PbP for any flags that may be on the account or any budgets listed for the customer’s refill amount. Once the flag or budget is found, proceed accordingly.

Low Sector Error Reboot.

010E

Reboot. Leave system off for a minimum of one minute.

A replacement print head will not resolve these errors.

Reboot. Leave system off for a minimum of one minute.

0112

Error occurred while trying to initialize printer. If this occurs during install, check that all shipping tape has been removed from the system.

Remove the power cord from both the wall outlet and the machine. Wait three minutes and reconnect power.

Make sure the ink cartridge cover is closed.

Ink carriage motor timing area. Usially occurs along with 2443 error when the system is rebooted.

See instructions for error 2443.

0802

Table 4-10 common error Messages

Action

Startup error. Reboot system.

Time out error. Reboot system.

1103

11F6

200C

200D

220C

24A3

The print carriage is not moving correctly or is jammed. This may also happen during refills.

Reboot for thirty seconds. If this fails to clear the error, reboot for three minutes. If the problem persists, see Table 4-7 for addtional troubleshooting information.

Weight capacity was not downloaded. Check the order to verify that weight capacity was ordered.

Follow local process to have DLA reset. Advise customer to perform download after 24 hours.

The system is not processing rates correctly. Check the order to verify that appropriate rating feature was ordered. Follow local process to have DLA reset. Advise customer to perform download after 24 hours.

Real time clock error — out of range. If this occurs during out-of-box setup, reboot the system.

Press continue to bypass the current clock time and complete the install process. Change clock time after installation is complete.

If this occurs after setup, confirm the current system time by printing a report. Attempt to update the system time from the options menu and then reboot the system.

Bad status message received from PbP. Confirm the system is installed on PbP and try to reconnect. Also confirm with PbP that funds are available for the customer.

Invalid meter graphics were detected. Try rebooting.

2443

2494

2544

2544/220C

Print head not at correct temperature. Is the system located near a heater, hot air vent or unusually warm area? Move to cooler area. Try rebooting to clear message. If unable to clear message, print head is suspect.

Ink carriage motor or sensor error. Grinding noise may also be heard. Check the capping station area to see if the capping station is broken or loose. If loose, try snapping it back into position. If this fails, replace purge unit.

Ink tank communication error. This error usually occurs when a new ink cartridge is installed.

Remove the ink cartridge and reinstall it. If this clears the error, install a new ink cartridge. If not, reboot.

Communication with the vault failed. Withdraw the system from service. You will not be able to remove funds.

Communication with the vault failed. Reboot the system for 30 seconds. If this fails, reboot the system for three minutes. This shoule clear the error.



Error

DE00

Table 4-10 common error Messages (continued)

Action

When trying to connect with the Data Center, either PbP is not set up to communicate with the meter or there is some other type of network problem.

1. Confirm the meter is installed at PbP, that the cusomer has not reached his or her credit limit, and that there are funds available to download.

2. If PbP is okay, there may be a network communication problem.

3. Make sure the meter is installed on the customer’s account.

4. Make sure the customer is not attempting to use a credit card.

5. Reboot the system for 30 seconds. If tis fails, reboot the system for three minutes.

6. If the meter was installed at PbP, have the customer change to the local AT&T number and attempt to connect again.

7. You must reboot after every DE00 error.

Location code not installed during setup.

Location Code

Required

EMD

Invalid User ID/

Password

Meter not

Authorized

Message

The meter can’t confirm that its memory is working. Withdraw the system from service. If funds are in the meter, flag as QAR (Question of Accurate Registration).

Usually Occurs during install.

1. Press CLEAR.

2. Reboot for 30 seconds.

3. If the display returns to ENTER AMOUNT TO ADD TO METER, press CLEAR.

4. Select RETURN TO START to begin the install over again.

Link Negotiation

Failed

Check that system is connected to an analog line. Try using 1-800-590-4857, 1-866-297-8025 or a local access number.

1. Reboot system.

2. Press CLEAR when display prompts: DO YOU NEED TO ENTER A NUMBER TO REACH AN

OUTSIDE LINE?

3. Select QUIT INSTALL and YES/ENTER to confirm. Display prompts: NOT AUTHORIZED.

4. Press OPTIONS.

5. Press PAGE DOWN (SCROLL) two times.

6. Select Connect — Data Center.

7. Select Phone Parameters.

8. Select Change PB Phone Number.

9. Press YES.

10. Enter the alternate phone number an select OK.

11. Reboot system. Display prompts: DO YOU NEED TO ENTER A NUMBER TO REACH AN

OUTSIDE LINE?

12. Retry the connection again.

Low Sector Error Reboot.

010E Error occurred while trying to initialize printer. If this occurs during install, check that all shipping tape has been removed from the system.

Remove the power cord from both the wall outlet and the machine. Wait three minutes and reconnect power.

Make sure the ink cartridge cover is closed.

Same as Link Negotiation Failed error. See table entry above.



Error

No Dial Tone

Print Head/Ink

Tank not Detected

Rate Manager Not

Initialized

Weight Over

Capacity

37B6

Table 4-10 common error Messages (continued)

Action

See Table 4-8.

See Table 4-4.

See Table 4-9.

See Table 4-9.

2544, 2443

2546

Error on DM400c. Happens when transport is opened? Clear envelopes from paper path and reboot.

Errors during bootup - The PSOC is communicating with the PSD and it is taking too long. Solution - Leave error up for two minutes, then reboot.

Reboot to clear if softkey does not work.

372A Feeder error with C4 envelope.

2482 or 248B No Paper. Cause: Operator inserted a mail piece then pulled it back out and then put it in again during a batch.

DE1D

2412

Reboot to resolve.

Tape ran out and last tape did not print.

25xx

23xx iButton.

PSOC.

248B Mail jam caused by stream feed.



163C

163D

163E

163F-1658

1659

165A

165B

165C

165D

165E

Error

1600

1601-1627

1628

1629

1630

1631

1632

1633

1634

1635

162A

162B

162C

162D

162E

162F

1636

1637

1638

1639

163A

163B

Table 4-11 Motion control Processor (McP) Related error codes (16xx codes)

Description

No Error

Reserved

Failed to Feed

Printer Not Ready

TAR2 Exit Jam

Printer Error

Transport Jam

TAR1 Exit Jam

Tape Jam

Printer Over run

Trip Jam

Mail piece too thick (jam)

Print Head Fire Timeout

Printer Not Ready during Tape

Printer Error during Tape Printing

A ‘Run “ail” operation was attempted with mail in the transport area.

The Power Stacker is Full

Skewed mail piece (reported by DM400 only)

Mailpiece Hold Error (Differential Weighing)

CSpark Tape Stream Error

Jam at hand-off to the WOW Module

Mail Piece too long - happens if the WOW sensor signifying that the piece is in position to weigh is blocked and the WOW entry sensor is still blocked

WOW Done message not received by MMC in specified time (WOW Weighing timeout) - a 5 second timeout on the handshake with the weighing module.

WOW Re-Zero Error

WOW Weight Error

Reserved

Non-volatile Memory Failure

Invalid Parameter Checksum in NVM

Invalid Cycle Count Checksum in NVM

Invalid Jam Count Checksum in NVM

MCP Reset due to Watchdog Timeout

Bad Profile Command



1698

1699-16A1

16A2

16A3

Error

16A4-16AA

16AB

16AC

16AD

16AE

16AF

16B0

16B1

16B2

16B3

16B4

16B5

1667-167F

1680

1681

1682

1683

1684

1685

1686

1687

1688

1689

168A

165F

1660

1661

1662

1663

1664

1665

1666

168B

168C-168D

168E

168F-1696

1697

Table 4-11 Motion control Processor (McP) Related error codes (16xx codes) continued

Invalid Motor State

Invalid Position Move

Error erasing flash memory for download

Error saving flash memory after download

Servo Position Error

I2C Bus Error

DM360 Feeder reported a Power On Self Test error

DM360 Feeder Communications Timeout

Reserved

Flash File System (FFS): MCP profiles are not Loaded (don’t exist in FFS)

Flash File System (FFS): Requested Profile Group Doesn’t Exist in MCP Profile

Flash File System (FFS): Invalid binary Profile

Invalid “default” Switch Condition

The MCP Reset due to a Watchdog Timeout

The MCP reset due to an error condition (e.g., ESD)

The mail run was terminated by specified condition

The internal state “stack” overflowed (too many pushes)

The internal state “stack” underflowed (too many pops)

Clear of Debit Operation Occurred before Mailrun

The WOW isn’t Present but Should Be

The MMC is not Responding

Reserved

The WOW Unable to Weigh – Weight Unstable

Reserved

A Sealant Out Condition Exists

A Tape Out Condition Exists

Reserved

Interlock Cover Open Event

Interlock Cover Closed Event

Description

Reserved

Power Stacker Full

WOW Error

The Weight Break Table Entries were Sent out of Sequence

Negative Weight Calculated

Weight not Valid for Mail Type

Weighing Error (unstable - maximum number of samples exceeded)

Weighing Error (no tare achieved - maximum number of samples exceeded)

WOW asked to weigh without calibration (calibration required)

Compute Rezero is Outside +/- 20 grams

Compute Rezero is Outside +/- 2 grams

Requested Operation Cannot be Performed in the Current State.



16B6

16B7

16B8

16B9

Table 4-11 Motion control Processor (McP) Related error codes (16xx codes) continued

Feeder Hardware Not Detected

The Requested Operation is invalid

The Feeder has not enumerated in a timely fashion

The firmware update has failed.

16BA No firmware has been installed in the UIC.

16BB-16FD Reserved

16FE

16FF

Branch-to Profile or Segment doesn’t exist

Requested Profile not available to be run



Error

2201

2202

2203

2204

2205

2206

2207

2208

2212

2213

2214

2215

220B

220C

220D

220E

220F

2210

2211

I-Button Specific PSD error codes Group 2 (21xx):

This class of errors is reported by the Janus UIC when there are image generator errors.

2209

220A

2216

2217

2218

2219

221A

Table 4-12 DM100i/DM200i Image Generator errors (22xx)

Description

Font, graphic, barcode, or text ad component had wrong schema version

Too many “indicia” components in the region map OR too many “town circle” components in the region map(s).

Wrong state to do the requested operation

Someone requested a change in the date duck state when there is no date field

Someone requested a change in the EB duck state when there is no Entgelt Bezahlt

Someone requested a change in the PIN duck state when there is no PIN field

Someone requested a change in the TL/TC duck state when there is no town line field and no town circle

The region maps weren’t numbered consecutively OR the id of the first region map wasn’t 0 (zero) OR the region map didn’t contain an indicia component or a permit component or a tax graphic component or a date/time component OR the region map had both a normal/low indicia component and a leading/ lagging indicia component OR the region map had both a normal indicia component and a low value indicia component OR the region map had a combinations of indicia and/or permit and/or tax graphic and/or date/time components

Someone tried to set the indicia type to “low” when there is no low value indicia graphic component

IG_Reload was called. Now IG_LoadIndicia, IG_LoadPermit, IG_LoadTaxGraphic, IG_LoadAdInscr or

IG_LoadDateTime must be called before calling one of the “duck” functions or IG_LoadStaticVCRs or

IG_LoadVariableVCRs. Similarly IG_LoadReport must be called before IG_LoadNextReportPage.

Region map contained an invalid component type

Someone called IG_LoadIndicia or IG_LoadAdInscr when there is no indicia region map

Someone called IG_LoadPermit when there is no permit region map

Someone called IG_LoadTaxGraphic when there is no tax graphic region map

Someone called IG_LoadIndicia when there is no indicia type selected

Someone called IG_LoadPermit when there is no permit selected

The blob was missing data for a set of VCRs OR the name strings was missing from the TC graphic and it’s needed

The data for a graphic component was missing from the component structure given to IG_Powerup or

IG_Reload or IG_SetIndiciaType

Font used by a text ad is missing OR font used by one or more VCRs is missing OR 1D barcode font is missing

A region’s or VCR’s starting point (column or row) and/or ending point (column or row) isn’t within the print area

The width and/or height of a graphic or font is zero OR the max width and/or max height of a region is zero OR the width/height of a graphic is greater than the max width/height of the region that the graphic goes in

The address of the graphic or font character is zero OR the size of the graphic or font character is zero

The compressed data had a command byte with a byte count of zero

When the image data is decompressed, the graphic is bigger than the given height and width

The number of VCRs defined in the register groups doesn’t match the number of VCR location records

OR too many VCRs have been defined

A register group or text ad line or 1D barcode field has an unknown justification value.



221B

221C

221D

221E

221F

2220

Table 4-12 DM100i/DM200i Image Generator errors (22xx) continued

A register group has a field size that is too big OR the number of VCR definitions for a graphic doesn’t match the sum of all the register field lengths for the graphic OR the total number of VCRs for a region map is more than the max allowed.

The text ad works out to be wider than the ad region

The text ad works out to be taller than the ad region

The ad area doesn’t have any space except for the required border around the text ad

One of the text ad lines has a font ID that isn’t allowed to be used for text ads

Something failed previously in the image generator. It won’t work properly until IG_Powerup is called again

2221

2222

2223

2224

2225

2226

2227 – 223F Codes reserved for future image generator errors

Error codes for the Barcode Generator

2240

2241

Can’t match the number of ECC words to a polynomial array. This means there is a mismatch between the barcode information table and the list of polynomial arrays in the DmBcPrivate.c file

An ECC mode other than “Data Matrix” was specified in the barcode definition in flash even though only data matrix barcodes are supported

2242

Trying to print just an ad and/or an inscription, BUT no ad and no inscription have been selected –OR- there is no ad area and no inscription area in the indicia region map –OR- combination of the two previous conditions (e.g., only an ad selected, but no ad area in the region map)

Someone requested a change in the printed batch count duck state when there is no printed batch count field

Someone requested a change in the text entry duck state when there is no text entry region

Someone called IG_LoadDateTime when there is no date/time region map

Someone requested a change in the time duck state when there is no time field

While loading all the desired graphics into the print area, it was found that the total number of columns required was greater than the maximum number of columns allowed

2243

2244

2245

2246

2250

2251

2252

Based on the number of symbol rows & columns specified in the barcode definition in flash, can’t find its corresponding data in the barcode information table in the DmBcPrivate.c file

Number of barcode symbols is > the number currently supported by the software

Barcode memory space needs to be increased in the DmBcPrivate.c file

Barcode definition in flash indicates more data bytes in the debit certificate than will fit in the barcode data code words

Somehow the barcode characteristics were never transferred from the barcode definition in flash to the local global structure in the barcode generator

Somehow the length of the data for the 1D barcode is zero after all the spaces are removed from the data

The width of the generated 1D barcode is greater than the allocated width (if a horizontal barcode) or the allocated height (if a vertical barcode)

The amount of data for the 1D barcode is more bytes than will fit in the work buffer



Error

2300

2301

2302

2303

2304

2305

2306

Table 4-13 DM100i/DM200i Print head Security errors (23xx)

Description

Version mismatch error

Programming failure

Communication error

Fatal communication error

Communication timeout error

Seed mismatch error

Fatal programming error

24A4

24A5

24B1

24B2

24B3

24B4

24B5

24B6

2493

2494

2495

24A1

24A2

24A3

2484

2485

248B

248C

2491

2492

Error

2400

2401

2441

2442

2443

2444

2445

2446

2447

2481

2482

2483

Description

Table 4-14 DM100i/DM200i Print Manager errors (24xx)

General printer fatal error

Could not send intertask message

Purge pump motor or sensor failure

Cap motor or sensor failure

Carriage motor or sensor failure

Inside temperature out of range

Transport motor or encoder failure

ASIC motor drive time limit exceeded

Print carriage not detected.

E_PAPER_SKEW (Mail skewed)

E_NO_PAPER

E_PIECE_TOO_SHORT

E_PIECE_TOO_FAST (Operator inserted mailpiece too fast)

E_NO_PRINT (Paper error)

E_JAM (Mail jammed)

E_JAM_LEVER_OPEN (Jam lever open)

E_NO_INK

E_NO_INKTANK

E_INKTANK_ID

E_INKTANK_CHECKSUM

E_TANK_LID_OPEN

No Printhead

Incorrect printhead type

Printhead NVM checksum failure

Printhead temperature out of range

Printhead heater failure

E_MSG_SRC

E_MSG_DEST

E_MSG_ID

E_MSG_TYPE

E_MSG_PARAMETER

E_MSG_NA (Not appropriate message, like “Perform Printer Maintenance” in Seal Only Mode)



4-22

Error

251C

251D

251E

251F

2520

2521

2516

2517

2518

2519

251A

251B

2510

2511

2512

2513

2514

2515

250A

250B

250C

250D

250E

250F

2522

2523

2524

2525

2526

2527

2528

2501

2502

2503

2504

2505

2506

2507

2508

2509

Table 4-15 DM100i/DM200i BOB Task errors (25xx)

Description

Unknown intertask message or script request

PSD failed to reply to a message

PHC failed to reply to a message

External card failed to reply to a message

General communication failure

PSD USB driver failure

PHC 232 driver failure

External card t=0 driver failure

Internal Error encountered by SCM task

General device driver failure

Unknown intertask message

Access code procedural errorError

The requested operation is not installed

Required font not installed

Font download errorError

Error retrieving report hash

Error determining PHC power parameters

Error determining current printing mode

Error while deriving meter status

Error while updating the batch registers

Error while gathering report data

Error gathering ad information

Error gathering inscription information

Error while preparing download to PHC

Error while preparing to download a leading barcode image

Error while preparing to download a lagging barcode image

Error preparing to pre debit

Error preparing the PHC configuration record

Error while preparing the vendor key

Snippet signature is unacceptable to PSD (no longer used but left in for Error spec compatibility)

Indicia not found in flash

Indicia font not found in flash

Report not found in flash

Report font not found in flash

Town circle not found in flash

Town circle font not found in flash

Error reading UIC date or time

Error building a device message

Erroneous message script ID

Device message reply length is unexpected



2548

2549

254A

254B

254C

254D

2542

2543

2544

2545

2546

2547

254E

254F

2550

2551

2552

2537

2538

2539

253A

253B

253C

2531

2532

2533

2534

2535

2536

2529

252A

252B

252C

252D

252E

252F

2530

253D

253E

253F

2540

2541

Table 4-15 DM100i/DM200i BOB Task errors (25xx) continued

Unknown component ID in the print zone packed byte parameter

Unknown function ID in the print zone packed byte parameter

Message resent maximum number of times without response

Trouble retrieving a test print from FLASH

Current account has expired during a mail run

Error while preparing the trusted SW key

Unknown device ID found in a tealeaves table

Department account does not have enough funds

Department account has reached allowed mailpieces

Unknown department account Error

Error while getting info from an installed type “Misc” graphic

Error while getting info from an installed Swiss star

Error accessing a required Entgelt Bezahlt in flash

Error while trying to get bar code parameters from FLASH

Error while trying to get NPCG.BIN from external flash

Error while trying to get xxxPCG.BIN from external flash

Error while trying to get PRINTEST.BIN from external flash

Gate keeper model is unknown

Snippet handler was unable to retrieve a snippet from FLASH iButton® PSD communications driver, success but no expected event iButton® PSD communications driver, failure miscellaneous

Error while accessing a miscellaneous graphic in the flash

Error creating dynamic blob for image generator

Error creating static blob for image generator

Error creating report blob for image generator

Error logging postage value download message to shadow log

Error logging debit certificate to shadow log iButton® PSD communications driver, success but timeout error iButton® PSD communications driver, failure OS no event match error iButton® PSD communications driver, failure OS timeout error

SCM_CURRENCY_MISMATCH, Currency code mismatch between indicia graphic and psd

SCM_CMOS_GMTOFFSET_OUT_OF_RANGE, CMOS gmtGMToffset out of range, reset to defaults

SCM_PERMIT_NOT_FOUND, Error accessing a permit graphic

SCM_DATETIME_NOT_FOUND, Error accessing a date time graphic

SCM_PERMIT_BATCH_COUNT_SET_ERROR, Error setting permit batch count index

Error finding an auto inscription in flash

Auto inscription ID is not in range

Piece count end of life error

Failure to correct shadow log

Error logging postage value refund message to shadow log

Error in fnValidData, probably a missing table entry

Error in fnWriteData, probably a missing table entry




Parts No.

QC1-4685

Name

GUIDE, CABLE

Qty

1

Photograph Recommended

Initial

Stock Item

Note

X QC1-4692 ROLLER, PRESS,

UPPER

1

QC1-4706 KNOB, RELEASE 1

QC1-4727 ROLLER, LOWER 1,

SEAL

2

QC1-4728 ROLLER, LOWER 2,

SEAL

2

QC1-4787 SHEET, DRAIN 1 X

QC1-5127 COVER, TOP 1

QC1-5128 COVER, OPEN/CLOSE 1


5 • Parts List

QC1-5129 COVER, DECK 1

QC1-5130 FOOT, RUBBER 4

QK1-0716 SENSOR UNIT 1

QK1-0721 MOTOR, DC 24V 1

QK1-0726 MOTOR, DC 27V 1

QK1-0731 CONTROL PANEL UNIT 1

QK1-0732

(UK)

QK1-0734(Int)

QL2-0670

MODEM UNIT

ENCODER ASSY

1

1

QL2-0687 COVER ASSY, BOTTOM 1

5-2

X

X

X

X Does not come with bezel.

X


QM2-1335 TRANSPORT UNIT,

UPPER

1

QM2-1336 ROWEL UNIT 1

QM2-1337 PULLEY UNIT,

TENSION

1

QM2-1338 REGISTRATION UNIT 1

QM2-1339 TRANSPORT UNIT,

LOWER

1

QM2-1341 GUIDE, TRANSPORT 1

QM2-1342 SLIDE PLATE ASSY 1

QM2-1343 WHEEL ASSY, SLIDE, 1 1



X

X

X

X


5-3



QM2-1346 PRESS ROLLER

LOWER UNIT

1

QM2-1347 PURGE UNIT 1

QM2-1352 CARRIAGE UNIT 1

QM2-1353 ADJUSTER UNIT, BELT,

CARRIAGE

1

QM2-1354 ADJUSTER UNIT, 1,

TENSION

1

QM2-1355 ADJUSTER UNIT, 2,

TENSION

1

QM2-1356 CONNECTOR ASSY 1

QM2-1357 SENSOR UNIT, COVER,

TOP

1

5-4

X

X

X

X

X


QM2-1360 PRESS ROLLER UNIT 1

QM2-1361 SENSOR UNIT, EN-

CODER

1

QM2-1364 PRINT HEAD UNIT 1

QM2-1374 WASTE INK TANK UNIT 1

QM2-1377 TANK COVER ASSY 1

QM2-1406 ENCODER PCB UNIT 1

QM2-1420 CABLE, MODEM 1

QM2-1422 DC POWER SUPPLY

UNIT

1


X

X

X

X

X


5-5


QM2-1425 CONTROLLER PCB

UNIT

1

QU1-0066 PULLEY, 40T 1

QU1-0067 PULLEY, 16T/80T 1

QU1-2118 SPRING, COMPRES-

SION

1

QU1-2119 SPRING, TORSION 1



QU1-2122 SPRING, TENSION 2

5-6

X This part is not

Parameterized.

Cheaper to replace machine.

Not available as a spare part.



QU1-3024 PULLEY, IDLER 2

QU1-3025 PULLEY, DRIVE 1

QU1-3026 BELT, FEED 1

QU1-3027 BELT, TIMING 2

QU1-3028 BELT, TIMING 1

QU1-6014 WHEEL, SLIDE 5

QU1-6015 WHEEL 3

VT2-5018 SPACER 3



5-7


WG8-5364 PHOTO-INTERRUPTER 1

XB1-2300-605 SCREW, MACHINE

M3X6

42

XD2-1100-242 RING, E, Φ2.4

1

XD2-1100-502 RETAINING RING (E-

TYPE)

3

XG9-0531 BEARING 4


Pitney Bowes DM200i Series Service Manual & Parts List

DM100i/DM200i series

Mailing System

Service Manual & Parts List

Page

SecTION 1

Introduction

SecTION 2

Specifications

SecTION 3

Removal & Replacement

SecTION 4

Troubleshooting

SecTION 5

Parts List

1.1 PURPOSe

1.2 eQUIPMeNT cOVeReD

1.3 cONTeNTS

1.4 SAFeTY SUMMARY

1.5 eQUIPMeNT SAFeTY

WARNING!

2.1 MATeRIAL SPecIFIcATIONS

Material Specifications

Material (see figure below)

2.2 MAchINe SPecIFIcATIONS

3.0 external covers

3.0.0 Removing the Upper Cover Unit

3.0.1 Removing the Control Panel Unit

3.0.2 Removing the Lower Cover Unit

3.1 carriage Unit Related

3.1.0 Removing the Carriage Unit

3.1.1 Removing the Carriage Drive Motor

3.1.2 Removing the Head Holder Unit

3.1.3 Adjustment at installation of the carriage drive belt

3.2 Purge Unit Related

3.2.0 Removing the Waste Ink Tank Unit

3.2.1 Removing the Purge Unit

3.2.2 Removing the sensor PCB (1)

3.2.3 Removing the Purge Motor Unit

3.3 Lower Delivery Unit Related

3.3.0 Removing the Lower Delivery Unit

3.4 Upper delivery Unit Related

3.4.0 Removing the Encoder Sensor

3.4.1 Removing the Delivery Motor

3.4.2 Caution at the delivery motor installation

3.4.3 Removing the delivery belt

3.4.4 Removing the Upper Delivery Unit

3.4.5 Removing the encoder

3.4.6 Removing the Sensor PCB (2)

3.5 PcBs

3.5.0 Removing the Main PCB

3.5.1 Removing the Modular PCB

3.5.2 Removing the DC Power Supply Unit

4.0 Introduction

4.0.1 General Troubleshooting

4.0.2 Error Messages

4.2 Troubleshooting Tables

Table 4-1 Power ON and Initialization Faults

Table 4-2 Keyboard and Display Faults

Table 4-3 Mailing Machine Transport Faults

Table 4-4 Printing Faults

Table 4-4 Printing Faults (continued)

Table 4-4 Printing Faults (continued)

Table 4-5 Print carriage Faults

Table 4-6 Moistener Faults

Table 4-7 Miscellaneous Faults

Table 4-8 Modem/connection Faults

Table 4-8 Modem/connection Faults (continued)

Table 4-9 Integrated Scale Faults

I-Button Specific PSD error codes Group 2 (21xx):

Related manuals

Neopost

IS-350 | IM350

USPS

DM100i

CNAD

LDU Series

Neopost

CS-200

Pitney Bowes