6204 Maint Manual 7 10 Electrical Maint Faults Access

6204 Series
Low-Volume Inserter
6/2012
MAINTENANCE MANUAL
Electrical description
7
Electrical description ....................................................................................138

PCBs ..............................................................................................139
Display board ................................................................................140
Keyboard .......................................................................................141
Motor relay board ..........................................................................141
Connection board ..........................................................................142
Communication board (optional) ...................................................145
Main board ....................................................................................150
ID-tag (2994504Z) ........................................................................155
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063.1 Service Guide
138
PCBs
An overview of all PCBs:
7
Board name
A0004538 Assy Display blanco
Display board + Keyboard
or
A0004539 Assy Display Neopost
2975540V (110 V) or
063.1 Service Guide
Board number
Motor relay board
2975500D (220 V)
4
2992003U (regular) or
Connection board
2992001S (expanded) (optional)
Modem board
2992002T (optional)
5
2992000R (optional)
Communication board
2825900V or
Main board or
Pre-programmed main board
A0004922
2994504Z
ID Tag
139
Display board
Wiring display board
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063.1 Service Guide
140
Connector number
Cable number
J100
A0002705
J101
LC display CCFL
J103
LC display touchscreen
J104
LC display data
J210
2994544R
Keyboard
Wiring keyboard
7
Cable number
J100
2994544R
063.1 Service Guide
Connector number
Motor relay board
Wiring motor relay board
141
Connector number
Cable number(s)
J1
2994526X
J2
Main motor
115 V: 2989407Q
230 V: 2989406P
063.1 Service Guide
J3
not in use
51
2994526X
52
2994526X
54
2994526X
55
2994526X
124
2994526X
Connection board
a. Connection board, regular
Wiring connection board (regular)
142
Connector number
Cable number
J101
2994532D
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063.1 Service Guide
143
b. Connection board, expanded (optional)
Wiring connection board (expanded)
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063.1 Service Guide
Connector number
Cable number
J105
2994532D
J108
2994532D
Modem board
The modem board is attached to the expanded connection board.
144
Communication board (optional)
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063.1 Service Guide
145
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063.1 Service Guide
Wiring communication board
146
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063.1 Service Guide
Connector number
Cable number
J101
2994534F
J401
2994532D
J402
2994548V
J403
2994532D
147
J502
2994534F
Testpoints and LEDs on the communication board
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063.1 Service Guide
148
Testpoint
Name
Typical value
Function
TP101
GND
0V
Debug ground
TP102
GND
0V
Debug ground
TP105
+24V
24 V
Supply check
TP106
GND
0V
Electrical ground
TP201
SDO
Debug only
TP202
SDI
Debug only
TP203
SCLK
Debug only
TP205
PB 5
Debug only
TP206
PB 6
Debug only
TP207
PB 7
Debug only
TP208
PFO/CAL
Debug only
LED
Color
Name
Function
D201
Green
TestLED 0
No error heartbeat
D202
Green
TestLED 1
Modem activity
D203
Green
TestLED 2
Inserter communication
activity (USB link)
D204
Green
TestLED 3
Franking interface (FIF)

communication activity
D205
Green
TestLED 4
Service communication
activity
D206
Green
TestLED 5
Debug LED
D302
Red
Flsh wrt
Flash write in progress indication
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063.1 Service Guide
149
Main board
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063.1 Service Guide
Wiring main board
150
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063.1 Service Guide
Connector number
Cable number
151
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063.1 Service Guide
J100
2989030X
J101
2989036D
J102
2994526X
J500
2994520R
J501
2989020M
J502
2989022P
J600
2989030X
J601
2994524V
J602
2994522T
J650
2994536H
J700
2989010B
J701
2989018K
J800
2989028V
J801
2989024R
J802
2994530B
J901
2989032Z
J902
2989032Z
J903
2989032Z
J1000
2989408R (Reading head)
J1100
2994532D (Without communication board)

2994534F (With communication board)
J1102
2994532D (Without communication board)

2994548V (With communication board)
J1120
2994534F
J1201
2989034B
Testpoints and LEDs on the main board
152
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063.1 Service Guide
Testpoint
Name
Typical value
Function
TP100
+5V
5 volt
Supply check
TP101
-12V
-12 volt
Supply check
TP102
+12V
12 volt
Supply check
TP103
GND
0 volt
Electrical ground
153
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063.1 Service Guide
154
TP105
+24V
24 volt
Supply check
TP200
Window
5 volt
OMR window oscilloscope

trigger
TP201
DBG1
Debug only
TP202
DBG2
Debug only
TP203
DBG3
Debug only
TP204
DBG4
Debug only
TP205
DBG5
Debug only
TP300
TST1
Debug only
TP301
TST2
Debug only
TP500
ENV
1.2 volt
Envelope photocell
TP501
FLAP
1.2 volt
Flap photocell
TP502
LOC
1.2 volt
Loc photocell
TP503
EXIT
1.2 volt
Exit
TP505
PDSC
5 volt or 0 volt
Main pulsedisc signal
TP600
COSER
1.2 volt
Closer photocell
TP700
COLL
1.2 volt
Collator photocell
TP701
FO
1.2 volt
Folder photocell
TP800
PD COL
5 volt or 0 volt
Collator pulsedisc
TP900
FE-1
1.2 volt
Feeder 1 photocell
TP901
FE-3
1.2 volt
Feeder 3 photocell
TP902
DFC FE1
Depends on paper thickness
DFC out feeder 1
TP903
DFC FE3
DFC out feeder 3
TP904
FE-2
1.2 volt
Feeder 2 photocell
TP906
DFC FE2
DFC out feeder 2
TP1000
OMR OUT
Depends on paper reflection Analog OMR signal

and marks
TP1001
ReadHead
1. volt
Readhead photocell
LED
Color
Name
Function
D300
Green
TST1
No error heartbeat
D500
Green
PDSC
Main pulsedisc indication
D701
Green
FT1
Folding table 1 indication
D702
Green
FT2
Folding table 2 indication
D801
Green
PD COLL
Collator pulsedisc indication
D301
Red
TST2
Error heartbeat
D303
Red
Flash write
Flash write in progress indication
ID-tag (2994504Z)
Wiring ID-Tag
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063.1 Service Guide
Connector number
Cable number
J100
2994536H
155
Preventive
maintenance
8
Preventive maintenance ................................................................................156

Maintenance schedule ...................................................................157
160k Service visit ..........................................................................158
500k Service visit ..........................................................................159
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063.1 Service Guide
156
Maintenance schedule
Average preventive service visits should take place at approximately 160.000 inserts (see service menu, service
counters). The table below shows the intervals.
Please note that there is a statistical relationship between the actual average monthly volume and the service
requirements of the machine. Significant larger average volumes might double the yearly service requirements.
Maintenance
Number of cycles
Service visit
+/- 160.000
160k
+/- 330.000
160k
+/- 500.000
500k
+/- 660.000
160k
+/- 830.000
160k
+/- 1.000.000
500k
10
+/- 1.660.000
160k
11
+/- 1.800.000
160k
...
...
8
It is recommended to service the machine at least twice a year.
063.1 Service Guide
157
160k Service visit

Estimated time to do the 160k service is 1 hour.
Additional parts to be replaced at each 160k.
Description
Page
Item
Part
Quantity
Upper separation
roller
Upper separation
roller
2951167G
Rubber paper puller
Rubber paper puller
13
2040016R
Separation roller
(lower)
Lower separation
roller
59
2951168H
Upper separation
roller
Upper separation
roller
2951167G
2*
Rubber paper puller
Rubber paper puller
13
2040016R
Separation roller
(lower)
Lower separation
roller
59
2951168H
2*
Feed roller kit 3 station expert
Feed roller kit 2 station expert
(*) Depending on the configuration
063.1 Service Guide
General:
1.
Check with the operator if there are any problems detected.
2.
Visual inspection.
Vertical:
1.
Clean the photocells and check the function via the service menu.
2.
Check the alignment of the document hoppers.
Document feeders:
1.
Replace the separation rollers (upper + lower) of the automatic separation feeder.
2.
Replace all paper pullers of the feeders.
Inserter:
158
1.
Clean the sealing and closing area of the inserter.
2.
Clean the photocells and check the function via the service menu.
500k Service visit

Estimated time to do the 500k service is 3 hours.
Additional parts to be replaced at each 500k.
Description
Page
Moistening cloth
Moistening cloth
Feed roller 42
mm
Feed roller 42
mm
Jogger roller Oring
Item
Qty.
Remarks
2040306T
1 for spare
13
2732731U
Jogger roller Oring
2041876D
Pre-assembled
finger kit
Pre-assembled
finger kit
36
2045383G
Transportation
roller 30 mm
Transportation
roller 30 mm
27
2995420D
At insert
Brush
Brush
19
2720005N
3 for spare
Collating belt set Collating belt set 30

(3 pcs.)
(3 pcs.)
2952007G
Pressure roller
Pressure roller
21
inc. O-ring (assy) inc. O-ring (assy)
2952011L
Transportation
table (assy)
Transportation
table (assy)
47
2964567Q
Transportation
roller 38mm
Transportation
roller 38mm
28
2042977A
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063.1 Service Guide
Part
General:
1.
Check with the operator if there are any problems detected.
2.
Visual inspection.
Vertical:
1.
Clean the rollers of the vertical track.
2.
Clean the collating belts and check the tension of the belts.
3.
Check the tension of the driving belts.
4.
Slightly lubricate the bearings.
Document feeders:
1.
Clean the rollers per feeder.
2.
Clean the freewheel clutch in Pulley 28T- see item "17" in Section Document feeder unit (automatic) on page
256" - and lubricate it lightly.
3.
Clean the thickness detector and check it via the service menu.
Envelope track:
1.
Check the separation roller, turn it a little inwards when a flat side is present.
2.
Replace the O-rings of the jogger rollers.
3.
Clean the rollers of the envelope track.
4.
Check if the rollers are still clicked correctly.
Inserting area, loc and exit:

1.
Replace the transportation rollers 30mm - see item "49" in Section "Insert and Eject mechanism on page
248" - which are placed above the lower insert rollers.
2.
Clean other rollers in the loc.
3.
Clean braking plate assy. and cover loc - see items "9" and "21" in Section "Envelope closing mechanism".
4.
Replace the brushes and the moistening cloth.
159
5.
Clean the upper and lower sealing rollers.
6.
Clean the lower insert rollers.
7.
Replace all the fingers.
Drive mechanism:
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063.1 Service Guide
160
1.
Check the chain tension, lubricate lightly if necessary.
2.
Check the belt tension.
3.
Clean the pulse disc and the accompanying sensor.
4.
Lightly lubricate the bearings.
Fault Finding
9
Fault Finding ..................................................................................................161

Fault finding introduction ..............................................................162
Resolve problems remotely ...........................................................163
Troubleshooting Online Services ...................................................163
Error handling inserter ..................................................................164
Error handling franking machine ...................................................187
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063.1 Service Guide
161
Fault finding introduction

There are three kinds of errors:
Hardware related errors that make further paper processing impossible. The error screen displays a call
service pictogram.
Hardware related errors at which further paper processing is still possible.
Operational errors, in most cases paper flow errors.
An error may result into:
A soft stop. An error situation forces the machine to stop. After solving the problem the process can be
resumed. The machine part with the problem is directly stopped, but in other machine parts envelopes and
documents are transported to the next stop position.
A hard stop. An error forces the machine to stop and the process cannot simply resumed after solving the
error. The machine must be switched off. An example of a hard stop is the opening of a microswitch-guarded
cover. All main motor-driven moving parts of both the system are abruptly stopped. The process timing (based
on pulses delivered by slotted photocells) is completely disrupted.
If an error occurs in one of the parts of the system, an error screen is displayed. The display shows a screen showing
the following information:
An indication of the area in which the error occurred.
An error description.
A suggested solution behind the pointing hand.
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063.1 Service Guide
Press the i button to view more information about the occurred error and about the possible actions to avoid the
error from reoccurring. After solving the problem, press the reset button to reset the error (the error screen will
disappear).
Priority
Usually the error that appears first, is displayed first.
There are however some exceptions:
A hard stop error prevails over a soft stop error.
A soft stop error prevails over a divert stop error.
If a feeder hopper is empty the machine continues the process until the last complete set is handled.
As far as simultaneous errors in various system parts are concerned the priorities are: inserter, folder, vertical
transport, feeder.
162
Resolve problems remotely

For remotely diagnosing customer problems, check the following with the customer:
The machine type and serial number:
1. Look on the sticker (on the internal frame)
2. Open the front cover
3.
Read the machine type and serial number
The customer's Failure description. See Section "Failure description".

The error message coming with the failure. This can be checked by the supervisor:
1. Enter the supervisor menu
2. Select system info
3.
Read the last error
4.
Check the counter since last service visit
5.
Check the software versions installed
In case of a system with connectivity to online services, ask the supervisor to make a manual connection.
Select a follow up process:
1. Guide the supervisor through a remote resolution process (with or without online services). A trained remote
service engineer needs to be consulted.
2. When sufficient cycles have been done since last service visit, schedule a preventive maintenance visit.
Schedule enough time for both the engineer and the customer.
3. When there is no clue about the exact cause of the failure, schedule a corrective maintenance resolution
process. A trained field engineer needs to be consulted.
Troubleshooting Online Services
063.1 Service Guide
If it is not possible to connect the machine to the server, use this troubleshooting table to find the cause.
No sound after pressing "Connect"
Check if the preparations described in Preparations on page

197 are met.
Check modem volume in the configuration menu.
Check if the telephone cable is connected.
Check the wall socket, ask the customer if the telephone line is
patched.
Check if the dial tone is set to on in the configuration setting menu.
For some PABX telephone systems switch dial tone off.
Main menu -> Supervisor menu (pin 2546) -> Online Services ->
Configuration
163
Sound after pressing "Connect"
Check if preparations described in Preparations on page 197 are

met.
Check the telephone number, the telephone number can be found
on Neoweb.
Check in the service menu the IP address:
192.168.20.217 (Europe)
172.16.100.10 (USA)
Server settings -> Server port
Check in the service menu the Port number:
5001 (Europe)
1003 (USA)
Check in the service menu Suffix: Osiris.FR.FT
The system stops the automatic call if the call fails three times.
Execute a manual call. This also reschedules the automatic calls.
System stops automatic call
9
Error handling inserter
063.1 Service Guide
After pressing the i button in an error message screen, the display can show an error code.
The error format of inserter errors is as follows: INS-XXX-YYY. The FRM messages are explained in {cr} Error
handling franking machine on page 187 . XXX is an abbreviation that indicates a specific machine part.
The following machine areas/prefixes apply:
164
XXX
Explanation
Reference
BAT
Battery
Battery errors (BAT) on page 165
CLS
Closer
Closer errors (CLS) on page 165
COM
Communication
Communication errors (COM) on

page 166
CT
Collator
Collator errors (CT) on page 167
DC
DFC
DFC errors (DC) on page 167
DF
Document Feeder
Document feeder errors (DF) on

page 168
EH
Envelope Hopper
Envelope hopper errors (EH) on

page 169
EOP
Envelope Open
Envelope open errors (EOP) on

page 170
FOL
Folder
Folder errors (FOL) on page 170
INS
Insert
Insert errors (INS) on page 171
JOB
Job
Job errors (JOB) on page 171
LIC
License
License errors (LIC) on page 172
Motor
Motor errors (M) on page 173
MOD
Modem
Modem errors (MOD) on page 174
OLS
Online service
Online service errors (OLS) on page

175
OR
Reading head
Reading head errors (OR) on page

176
Photocell
Photocell errors (Pxx) on page 176
PB
PCB
PCB errors (PBx) on page 179
PD
Pulse Disc
Pulse disc errors (PD) on page 180
RE
Reading
Reading errors (RE) on page 181
SM
State Machine
Machine state errors (SM) on page

185
SW
Switches
Switches errors (SW) on page 185
SYS
System
System errors (SYS) on page 185
TR
Transport
Transport errors (TR) on page 187
Battery errors (BAT)

Message
Cause
Information
INS-BAT- 400
Technical failure
Power dip on communication board. OLS error.
At IN startup and configuration check (only if OLS is

switched on in service
menu).
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063.1 Service Guide
Error
Closer errors (CLS)

Error
Message
Cause
Information
INS-CLS- 110
Envelope closer failure
Envelope path not cleared

after previous jam, envelope
closing sensor readjustment
needed, dirty sealing track,
insert failures.
This error is generated if the

closer cell is covered at the
moment an envelope/ document should leave the insert
area.
INS-CLS- 111
Envelope closure failure
Envelope closing path not

cleared after previous jam,
slippage, dirty sealing track,
insert failures, skewing.

flap closer sensor is
covered too long. Longer
than the time that meets a
document transport of 550
flanks (approx. 275 mm).
INS-CLS- 290
Unexpected document at
exit
Document which should

Reset to continue.
have been removed wasn't
removed.
165
Communication errors (COM)
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063.1 Service Guide
166
Error
Message
Cause
Information
INS-COM- 900
Technical failure
INS-COM- 901
Technical failure
SCS/I2C protocol problem, System error. This error is

cables, connectors, PCBs. generated if something is
wrong with the SCS/I2C.
INS-COM- 902
Technical failure

INS-COM- 903
Technical failure

INS-COM- 904
Technical failure

INS-COM- 905
Technical failure

INS-COM- 906
Technical failure

INS-COM- 907
Technical failure

INS-COM- 908
Communication failure
Communication failure.
INS-COM- 910
Technical failure
Communication lost
ISIS link down between
main board and communic- between inserter and communication board.
ation board.
INS-COM- 911
Technical failure
Communication lost
Reset to continue.
between inserter and connection board.
INS-COM- 930
No communication
Communication error
Check cables and connectbetween inserter scanner or ors.
BSPI PC.
Call service.
Collator errors (CT)

Error
Message
Cause
Information
INS-CT1- 100
Document transport failure Document type, document This error is generated if the
path blockage, photocells collator entry cell is covered
too long. Possible causes:
dusty, photocells defect.
too stiff material, collator
blocked.
INS-CT1- 110
Collator stop error
INS-CT1- 120
Document transport failure Document set missing from

collator, photocells readjustments needed, photocells
defect.
This error is generated if no

documents arrive at the
folder entry cell. Possible
causes: paper crash or the
operator pressed the stop
button, removed the set
from the collator and
pressed start.
INS-CT1- 290
Unexpected document at
collator
Collator not cleared after

previous emergency stop.
During initialization of the

collator a set is seen under
the folder entry cell. The
collator is initialized after
fatal feeder errors, after collator errors and after a
change of job.
Error
Message
Cause
Information
INS-DC1- 401
Technical failure
DFC defect, cables defect. This error is generated in a

job where the DFC is turned
on while it is defect. This
error returns after each
change of job.
Incorrect collator stop posi- This error is generated if it

takes too long before a set
tion, mechanical failure.
arrives at the folder entry
sensor. Is only checked at
job start.
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063.1 Service Guide
DFC errors (DC)
167
INS-DC1- 402
Feeding failure
Document separation fail- This error is generated

ing, DFC defect, cables de- when the DFC can not see
the difference between pafect.
per being present or not
present. This can be caused
by a continuous flow of paper (no space in between
sheets) or by a defect in the
DFC. After reset, a new reference value is taken.
When still no difference is
measured, error INSDC1402 shows. There is a defect in the DFC.
INS-DC1- 402
DFC failure
DFC defect, cables defect. This error is generated if the

DFC can not be adjusted.
Document feeder errors (DF)

Error
Message
Cause
Information
INS-DF1- 000
Empty feeder
Empty feeders, wrong document type, document width

setting, manual document
separation adjustment.
This error is generated if a

feeder is empty. This can be
put right by refilling the
feeder and pressing Reset.
This is no fatal error, after
restarting the job, the set
will be finished. In order to
do a restart after this error,
press the start button.
INS-DF1- 110
Document stoppage
Blocked document path,

document separation adjustment (manual separation
only), document type, document job settings, photocells dusty.

feeder processes a document and it is found that the
document is at least 50%
longer than the document
size that was set up for that
feeder in that particular job.
This is a fatal error.
INS-DF1- 200
Document too short
Incorrect document type,

document job settings, pho- feeder processes a docutocell readjustment needed. ment with a length that is
more than 45 mm shorter
than the document size that
was set up for that feeder in
that particular job. This is a
fatal error.
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063.1 Service Guide
168

feeder processes a document that is more than 20%
longer than the document
size that was set up for that
feeder in that particular job.
This is a fatal error.
INS-DF1- 201
Document too long
Document separation adjustment (manual separation

only, document type, document job settings, photocells dusty.
INS-DF1- 300
Feeding failure

Incorrect thickness reference, irregular document sheet on which the DFC is
types, DFC defect or loose. adjusted was a double
sheet. This error can only
be generated with the first
sheet that a feeder processes after adjustment
(when this sheet is thinner
than the one that was used
for the adjustment). This is
a fatal error.
INS-DF1- 301
Document too thick
Document type, document This error is generated if a

separation adjustment
feeder inserts a double
(manual separation only), page. This is a fatal error.
separation rollers worn out.
Envelope hopper errors (EH)

Message
Cause
Information
INS-EH1- 000
Empty envelope hopper
Empty hopper, wrong envelope type, envelope width

setting, envelope separation
adjustment, envelope feeding angle.
This error is generated if it

takes longer than 15
seconds to detect an envelope at the envelope track
sensor after the envelope
track was started.
INS-EH1- 200
Envelope too short

Incorrect envelope type,
envelope job settings, pho- envelope is measured
tocell readjustment needed. shorter than 75 mm. Also
when envelope height is
measured shorter than adjusted envelope height
minus 20 mm.
INS-EH1- 201
Envelope too long
Envelope separation adjustment, envelope type, envelope quality, envelope job

settings, photocells dusty.
063.1 Service Guide
Error

closed envelope is measured higher than 182 mm
(162 mm + 20 mm tolerance) or if the envelope is
measured higher than the
adjusted envelope height
plus 20 mm.
169
Envelope open errors (EOP)

Error
Message
Cause
Information
INS-EOP- 300
Envelope not open
Envelope exit path, slippage, envelope type, inserting failure, flap closer
sensor.

envelope does not arrive
within 400 mm (800 flanks)
at the exit cell, after detecting the envelope by the
closer switch.
Folder errors (FOL)
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063.1 Service Guide
170
Error
Message
Cause
Information
INS-FOL- 100
Folder entry blockage
Document feeding, document separation, document

path not cleared after previous stoppage, skewing of
set, slippage.

folder entry cell is covered
longer than 500 pulses
(about 475 mm). Caused by
incorrect folder transport, or
the document is blocking in
collator.
INS-FOL- 111
Folding failure
Document set thickness,

mechanical defect in first
fold table, folding sensors
defect.
This error is generated if

500 ms after powering the
clutch of the first fold table
no flank is detected on the
curve disc sensor of the first
fold table. Possible causes:
fold table blocking by a not
foldable document (stiff material), mechanical defect on
fold table, clutch or sensor.
INS-FOL- 112
Folding failure
Document set thickness,

mechanical defect in first
fold table, folding sensors
defect.

500 ms after powering the
clutch of the second fold
table no flank is detected on
the curve disc sensor of the
second fold table. Possible
causes: fold table blocking
by a not foldable document
(stiff material), mechanical
defect on fold table, clutch
or sensor.
INS-FOL- 120
Document stoppage
Set not removed after job

change.
This error is generated

when paper is left in the
folder after a job change.
Insert errors (INS)

Message
Cause
Information
INS-INS- 100
Document inserting failure Insert fingers, envelope stop

position, envelope job settings, document skewing,
document, slippage, document feeding, envelop
feeding.

insert cell is covered too
long during inserting. Too
long means longer than 400
mm (800 flanks).
INS-INS- 101
Envelope stoppage
Blocked envelope path, envelope separation adjustment, envelope type, envelope job settings, dusty photocells, slippage.

flap sensor is covered more
than 690 flanks (approx.
345 mm).
INS-INS- 102
Document stoppage
Blocked document path,

slippage.

called document does not
arrive at the insert cell.
INS-INS- 103
Insert area blocked
Blocked document or envel- This error is generated if a

document covers the insert
ope path after previous
cell at the moment the sysstoppage.
tem is started.
INS-INS- 290
Unexpected document
Document path not correctly This error is generated if a

cleared after previous error, document arrives at the inslippage, inserting failures. sert area at a not expected
moment.
INS-INS- 290
Unexpected document
Document path not correctly This error is generated if the

cleared after previous error, insert cell is covered at the
slippage, inserting failures. moment a document is
called.
INS-INS- 303
Document length failure
Insert fingers, envelope stop

position, document job settings, document skewing,
document slippage, document feeding.
This error is generated if on

two inserts directly after
each other a length difference is measured of more
than 42 mm (84 flanks).
This means irregular inserting (slip on insert rollers?).
Error
Message
Cause
Information
INS-JOB- 000
Empty feeders
Empty feeders, wrong document type, document width

setting, manual document
separation adjustment.
This error is generated if all

feeders are empty during
the Automatic job scanning
session.
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063.1 Service Guide
Error
Job errors (JOB)
171
INS-JOB- 201
Unauthorized job
Incorrect document job set- This error is generated if a

tings, dongle reading failure. 2 station machine is reconstructed to a 1.5 station
machine (dongle removed)
and a job is started that
does not comply with the
specifications for a half station. This is the case when
the document length for that
half station is adjusted to
>156 mm and/or to multifeed.
INS-JOB- 300
not possible
Not supported documents This error is generated

and envelope type detected when due to folder limitations the fold can not be
for Automatic job.
made that was calculated
based on measured document lengths and envelope
height.
License errors (LIC)
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063.1 Service Guide
172
Error
Message
Cause
Information
INS-LIC- 200
Invalid license key entered Invalid licence key, or licence key for other machine.

entered license key (via supervisor menu) could not be
recognized or translated into a valid option by the system. This error can also be
generated when the factory
license key could not be recognized or translated to a
set of valid options.
INS-LIC- 400
Update options failed
ID/Option memory defect.

addition of an option into the
option memory fails, because the encrypted contents of the ID tag does not
match what is expected.
INS-LIC- 401
Option memory failure
Option memory defect or

general hardware defect.

ID tag is not seen during
power up. Reason can be
that option wiring is not
connected or that there is
something wrong with the
hardware.
INS-LIC- 402
Option memory failure
ID memory empty, wiring

defect, ID/Option memory
defect.

ID tag could not be read,
both the system ID or the
options. Also when the system code is not valid (depends on the alphabet
characters in the system
ID). This error will occur
every time the system is
started, and the system can
function without the options.
INS-LIC- 403
Invalid data in option

memory/ID tag
The option data in the tag is

not valid. It has a wrong
checksum. The most likely
cause of this failure is either
an error in the hardware or
the connection of a wrong/
uninitialized tag to a machine.

entered license key (via supervisor menu) could not be
recognized or translated into a valid option by the machine.
Error
Message
Cause
Information
INS-M03- 400
Technical failure
Blockage of collator, collator This error is generated if the

pulse disc defect, collator DC motor of the collator is
motor defect
not running while it is supposed to. The error is
shown when there are no
pulses detected for 100 ms.
This can be caused by:
Motor errors (M)
9
063.1 Service Guide
a mechanical blockade as a result of

which the motor is
running roughly
not properly functioning of the pulse disk
of the collator
a defect to the electric
drive of the collator
motor
a defect motor
173
Modem errors (MOD)

Error
Message
Cause
Information
INS-MOD- 200
OLS message: at the initiOLS dialling interrupted by The user/supervisor

user
pressed the disconnect but- ation of a new OLS connection and the drilling is interton while dialing out.
rupted by user.
INS-MOD- 300
No dial tone
The modem failed to detect

a dial signal. Could also
happen if the phone line is
not connected.
OLS message: at Osiris

connection set up.
OLS message: at the initiation of a new OLS connection and there is no incoming phone line available at
the server or there is congestion on the public phone
network. Try again later
Check the phone line (e.g.

by connecting a normal
analogue phone and listening to the receiver. If there
is a Dalton, try disabling the
dial tone detect in the OLS
configuration screen on the
device).
INS-MOD- 301
OLS dialling interrupted unexpectedly
INS-MOD- 302
OLS line busy
The phone number being

dialed is busy.
INS-MOD- 303
No carrier
The modem failed to negoti- OLS message: at the initiate with the modem of the ation of a new OLS connecserver.
tion. This could have multiple reasons. E.g. the quality of the line is bad or the
negotiation with the modem
of the server failed. Try
again later.
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063.1 Service Guide
If it continues to fail repeatedly verify line signal

quality for example by connecting an analogue phone
to the line and listen to the
dial tone, try to make an external call.
174
INS-MOD- 400
Technical failure
Modem not ready or serial OLS error at IN startup and

port initialization of modem configuration check (only
failed.
when OLS is switched on in
service menu).
INS-MOD- 401
No analogue phone detec- There is no analogue phone OLS message: at Osiris

ted
line connected to the ma- connection set up.
chine or the line is faulty.
Check the phone line.
INS-MOD- 580
Technical failure
No modem available/ detected, modem defect, modem

not plugged in, cable defect,
no connector board, connector board defect.
OLS error. At IN startup and

configuration check and
modem is expected because of service settings or
licence.
Online service errors (OLS)

Error
Message
Cause
Information
INS-OLS- 000
New online service messages
New OLS message on

communication board.
OLS message. At start up

of system when OLS is enabled and new messages
are available in OLS menu.
INS-OLS- 300
OLS server not responding
INS-OLS- 301
OLS server not ready
INS-OLS- 302
OLS connection refused by At setting up an OLS connection the authentication

server
process of the system failed
because system is not allowed to connect.
The connection to the server succeeded but the server
doesn't allow this device to
communicate with the server.
OLS message: the IP settings are not correct.

Check IP number and port.
Also it could be possible
that the device is not allowed to authenticating.
OLS message: the device
is not known by the server.
Check on the OLS server if
this device serial number is
known by the server.
INS-OLS- 303
Protocol error
INS-OLS- 304
OLS connecting to server

failed (timeout answer)
INS-OLS- 305
Low infrastructure quality
INS-OLS- 306
Automatic stats upload

failed
INS-OLS- 307
Configuration upload/down- The upload of the configura- Ask OLS server administrattion information is interrup- or to investigate.
load failed
ted.
INS-OLS- 308
Automatic software download failed
A software download is inter- Ask OLS server administratrupted.

or to investigate.
INS-OLS- 309
Automatic job download

failed
A job download is interrup- Ask OLS server administratted.

or to investigate.
INS-OLS- 310
Automatic feature download A feature download is inter- Ask OLS server administratfailed
rupted.
or to investigate.
INS-OLS- 311
Automatic flex code down- A flex OMR download is in- Ask OLS server administratload failed
terrupted.
or to investigate.
INS-OLS- 312
Auto connection failure
Automatic connection failed.

Statistic buffer overflow
>95%, batch data might be
lost.
Ask OLS server administrator to investigate.
063.1 Service Guide
The upload of statistics is

interrupted.
OLS error. During operations, when stop or clear is

pressed and the system is
stopped, and allocated
memory is getting full. Only
when OLS is on en options
statistics is enabled.
175
Reading head errors (OR)

Error
Message
Cause
Information
INS-OR1- 400
Technical failure
Reading head dirty, LED

defect, photocell defect,
cables defect.
OMR error. This error is

generated if the LED in the
reading head is defect.
Photocell errors (Pxx)

The coding of the photocells is as follows:
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063.1 Service Guide
Photocell code
Reference photocell
P01
Envelope track sensor
P02
Envelope flap sensor
P03
Insert table sensor
P04
Exit sensor
P05
Closer sensor
P06
Folder entry sensor
P07
Vertical track sensor
P08
Collator entry sensor
P09
Feeder sensor
P10
Feeder sensor
P11
Feeder sensor
The error list below covers all photocell errors.
The error numbers can be different for some photocells.
176
Error
Message
Cause
Information
INS-Pxx- 300
Photocell dusty
Low voltage received by the Dust error.

photocell (dusty).
DAC current becomes too
high during operation. You
are warned if the DAC current increases and the
sensor power decreases (<
0,8 V). This error is generated each 25 docs.
After pressing the reset button, the following warning
message appears:
1.
2.
3.
4.
INS-Pxx- 300
Sensor error
Too much voltage received

by photocell. Current cannot
be correctly adjusted (too
low)
Remove paper at
sensor position
Clean sensor with bellow or brush
Press OK to reset
sensor
SK4: The involved
photocell values are
reset. Go back to the
main menu.
Overexposure receiver error.
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063.1 Service Guide

involved photocell is too
sensitive: during adjustment
the LED current becomes
too low (adjustment after 25
sheets). Lower limit is 5/256
x100%.
message appears:
1.
2.
3.
4.
Remove paper at
sensor position
Press OK to reset
sensor
SK4: The involved
main menu.
177
INS-Pxx- 302
Technical failure
LED current adjusted too Photocell adjust error.

low. Photocell sensor adjust
error
involved photocell can not
be adjusted correctly. The
DAC current is too low
(<5/256 X100%). Only when
the system is started the
first time or when the system is adjusted again after
a dusty error.
After a reset, the error message disappears. If the particular photocell is not
needed for the selected job,
the job can still be carried
out. If the photocell is
needed or if a new job is
selected, the error appears
again as soon as the start
button is pressed or a test
run is performed.
INS-Pxx- 302
Sensor error
Voltage received by the

Dust error.
photocell is too high due to
dust fall off
voltage in the involved photocell receiver suddenly increases significantly (e.g.
by dust that falls off).
Danger arises that the
voltage in de receiver (> 1,5
V) stays too high when paper is present.
063.1 Service Guide

message appears:
1.
2.
3.
4.
178
Remove paper at
sensor position
Press OK to reset
sensor
SK4: The involved
main menu.
INS-Pxx- 303
Technical failure
Sensor adjust error. Led

current cannot be adjusted
to have photocell voltage
between 0,8 and 1,3 V.
Dusty, incorrect positioning,
incorrectly assembled.
Photocell adjust error.

involved photocell can not
be adjusted correctly.
Transmitter power is too
high and receiver power is
smaller than 0,8 V (e.g.
contamination, not correctly
connected, not correctly
aligned). Only when the
system is started the first
time or when the system is
adjusted again after a dusty
error.
run is performed.
INS-Pxx- 401
Technical failure
Sensor defective. Photocell, Power up photocell deteccables or connectors defect. tion error.
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063.1 Service Guide
This error is generated if no

LED current is detected in
the involved photocell (LED
incorrect or not connected)
during powering up the system.
run is performed.
PCB errors (PBx)

Error
Message
Cause
Information
INS-PB1- 300
Technical failure
FRAM chip contains old

data structure.
System error. This error is

generated during starting up
of the machine.
INS-PB1- 301
Technical failure
FRAM chip contains corrupt System error. This error is

data.
generated during reading of
a data block.
179
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063.1 Service Guide
INS-PB1- 402
Technical failure
FRAM chip is not available. System error. This error is

generated during starting up
or operation of the machine.
INS-PB1- 403
Technical failure
FRAM chip is not formatted. System error. This error is

generated if the machine is
started up (at least) the first
time.
INS-PB1- 404
Technical failure
INS-PB2- 301
Technical failure
FRAM not formatted.
During start up, and

OLS/FIF is enabled.
INS-PB2- 301
Technical failure
FRAM contains old data

structure.
During start up, and

OLS/FIF is enabled
INS-PB2- 301
Technical failure
FRAM contains corrupt

data.
When reading data block
INS-PB2- 400
Technical failure
Clock update received from During run, system should

server failed.
continue.
INS-PB2- 406
Technical failure
INF error. At IN startup and

Internal cables defect or
communication/connection configuration check (only
when INF options are enboard defect.
abled). Also when INF job
is started or INF job is edited and no communication
is possible.
INS-PB2- 407
Technical failure
FRAM chip not available on During start up, and

OLS/FIF is enabled.
INS-PB2- 408
Technical failure
PCB communication board During start up of the system (and OLS/ FIF is enfailure.
abled).
Pulse disc errors (PD)
180
Error
Message
Cause
Information
INS-PD1- 400
Technical failure
Main motor defect, pulse

disc defect, cables defect.
System error. This error is

generated if the pulse disk
of the main power does not
generate enough pulses or
if the width of the pulses is
irregular. The motor is too
heavily loaded or the pulse
disk is defect. For the
boundaries, refer to the
pulse disk test in the service
menu.
Reading errors (RE)

Message
Cause
Information
INS-RE1- 000
Reading stop
Stop mark read.
OMR error. Remove the set

and press Reset. A complete set is on the collator
and must be handled
manually.
INS-RE1- 003
Suspected set
Incomplete sets collected

after reading error.

generated after an earlier
appeared reading error. The
paper run command insert
is read. The earlier appeared reading error probably occurred halfway a set,
because of which that set
and the next one are incomplete.
INS-RE1- 003
Final set part
Incorrect marks read, read- OMR error. This error is

generated if the remains of
ing job settings.
the set (until the insert sign)
are collated after removing
an incomplete set and
pressing Reset and Start for
error INS-RE1-312. If again
the maximum amount of
sheets in a set is exceeded,
error INS-RE1-312 is generated again.
INS-RE1- 300
Wrong reading window pos- Incorrect reading job setition

tings.
INS-RE1- 302
Reading error
9
063.1 Service Guide
Error

generated when the reading
window is behind the end of
the paper.
Less marks read than expec- OMR error. This error is

ted.
generated if less reading
code marks are seen, than
possible with the chosen
reading code. The set can but does not need to - be
taken out of the collator.
After a restart, the rest of
the set is finished, after
which error INS-RE1-003
shows.
181
Reading error
More than 1 basic command (accumulate/ insert/

divert/ stop mark) read.
INS-RE1- 304
Reading error
No basic command (accu- OMR error. This error is

mulate/ insert/ divert/ stop/ generated if no barcode line
that indicates the paper run
start/ safety mark) read.
(accumulate/ insert/ divert/
stop mark) is found. Start
and safety mark included.
The set can - but does not
need to - be taken out of the
collator. After a restart, the
rest of the set is finished,
after which error INS-RE1003 shows.
INS-RE1- 305
Reading error
Matching varies within the

set.
INS-RE1- 306
Reading error
Sequence number of docu- OMR error. This error is

ment does not match with generated if the order, as
guarded by the sequence
previous document.
numbering of the documents, is no longer correct.
after which error INSRE1003 shows.
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063.1 Service Guide
182

generated if more paper
running assignments are
readable in the bar code.
INS-RE1- 303

generated if one sheet within a set has another match
number (only with Flex
code). The set can - but
does not need to - be taken
out of the collator. After a
restart, the rest of the set is
finished, after which error
INS-RE1-003 shows.
INS-RE1- 307
Reading error
Matching number of set is OMR error. This error is

not correct (related to previ- generated if the match
number of the previous set
ous set).
does not join in with the
match number of the current
one (only with Flex code).
INS-RE1- 308
Reading error
Parity of the marks read is

not correct. Reading window incorrect? Reading
marks incorrect. Check
reading settings.
INS-RE1- 309
Reading error
A mark is read at an illegal OMR error. This error code

is generated when a barposition.
code line is read that can
not be in that particular position (too many lines or inconsistent with other lines).
Reading error
Incorrect marks read, reading job settings, slippage,

reading head adjustments
needed.
9
063.1 Service Guide
INS-RE1- 310

generated if the parity of a
read code is incorrect. The
set can - but does not need
to - be taken out of the collator. After a restart, the rest
of the set is finished, after
shows.

generated if the position of
a barcode line is moved that
far, that it has arrived in the
so called forbidden zone.
(The forbidden zone is an
area halfway two lines, that
is defined as a percentage
of the line distance.) The set
can - but does not need to
- be taken out of the collator. After a restart, the rest
shows.
183
INS-RE1- 311
Reading error
Incorrect marks read, read- OMR error. This error is

generated if more barcode
ing job settings, reading
lines are present than alwindow too long.
lowed for the used barcode
(only for OMR level 0). The
set can - but does not need
to - be taken out of the collator. After a restart, the rest
shows.
INS-RE1- 312
Too many documents
Set size exceeds maximum

number from reading job
settings, incorrect marks
read.
OMR error. Remove the set

and press Reset. To restart
the system, press Start.
During collating through
reading, a set should always be completed. However, a maximum set size is
indicated in the OMR setting
menu (attachments are included). When this maximum size is reached, the collating stops and this error is
generated. This does not
happen during overlapping
supply from the feeders.
INS-RE1- 313
Reading error
No safety mark read.

generated when a safety
mark is not read. The set
may be removed from the
collator. Pressing Reset and
Start will result in error INSRE1- 003 Suspected set.
INS-RE1- 314
Reading error
Group start mark error.

generated when a group
start mark is not read. The
set may be removed from
the collator. Pressing Reset
and Start will result in error
INS-RE1-003 Suspected
set.
INS-RE1- 315
Reading error
Group end mark error.

generated when a group
end mark is not read. The
set may be removed from
the collator. Pressing Reset
and Start will result in error
INS-RE1-003 Suspected
set.
INS-RE1- 324
Reading error
Wrong start of set.
The new set does not start

with N=1. Remove documents.
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063.1 Service Guide
184
INS-RE1- 325
Reading error
Sequence error.
N is not one more than the

previous N in the same set.
Reset & start to finish set.
INS-RE1- 326
Reading error
M cannot be 0.
Remove documents.
INS-RE1- 327
Reading error
M changed in set.
Remove documents.
Machine state errors (SM)

Error
Message
Cause
Information
INS-SM1- 301
Envelope stoppage
Envelope lost in envelope

track.
Remove envelope.
INS-SM4- 301
Document transport failure Document transport failure. Remove documents check

exit.
Switches errors (SW)

Message
Cause
Information
INS-SW1- 200
Cover open
Front cover open, cover

switches defect or loose,
envelope track sensors.

during a run the front cover
is opened.
INS-SW2- 200
Cover open
Collator cover open, cover This error is generated if

during a run the collator
cover is opened.
INS-SW3- 200
Cover open
Top cover open, cover


during a run the top cover
is opened.
Information
9
063.1 Service Guide
Error
System errors (SYS)

Error
Message
Cause
INS-SYS- 000
Preventive maintenance
needed
Total counter equal to Ser- This error is generated if the

vice Counter, Service
next visit service counter
counter incorrect.
value is reached. The message will appear at system
start.
INS-SYS- 200
Serial number already

present in ID tag
Machine's software and

identity are setup already.

machine is prepared in the
factory and later on an attempt is made to prepare
the machine again. Preparation (flashing and setting
serial number) should only
be done on pristine machines.
185
INS-SYS- 300
Technical failure
Connection board restarted. Reset to continue.
INS-SYS- 304
Technical failure
Reset to continue.
between inserter and communication board.
INS-SYS- 501
Illegal configuration
Illegal configuration detec- This error is generated

ted.
when the serial number in
the ID-tag 2994504Z does
not match the serial number
in the Fram of the main
board. The machine is
blocked from operating, because the counters in the
Fram and the ID-tag
2994504Z do not match.
See Remove blockage on
page 41.
INS-SYS- 563
Technical failure
Incorrect software in commu- At IN startup and configuranication board or inserter tion check. Communication
board.
board is expected because
of service settings or licence.
INS-SYS- 580
Technical failure
System serial number

memorized in communication board is not the same
as on ID tag. Most likely because of exchanged connection board from an existing
system.
INS-SYS- 581
Technical failure
OLS or INF error. At IN

Communication board
missing or defect, or internal startup and configuration
check. Also when INF info
cables or PCB defect.
is needed (INF job start, INF
job adjust). Communication
board is expected because
of service settings or licence. Cause: internal
Cables, PCB defect.
INS-SYS- 582
Technical failure
The installed modem could OLS error. At IN startup and

not be detected as a legal configuration check a modem is expected because
version.
of service settings or licence.
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063.1 Service Guide
186
OLS or INF error. At IN

startup and configuration
check. Communication
board is configured on a
different inserter than the
current inserter (based on
serial number). After reset
error: choose Continue
without action or Initialise
Transport errors (TR)

Error
Message
Cause
Information
INS-TR2- 110
Document transport failure Document path blockage, This error is generated if the
slippage, vertical track pho- document does not arrive in
time at the collator entry cell
tocells dusty.
(if transport time between
leaving feeder and arriving
at folder entry exceeds 700
mm (750 pulses)).
INS-TR2- 290
Unexpected documents in
vertical track
Document stoppage at ver- Remove documents.

tical track photocell.
INS-TR3- 120
Envelope stoppage
Blocked envelope path,

slippage.
INS-TR4- 110
Envelope stoppage
Transport failure between

envelope closing and envelope exit.
INS-TR4- 120
Envelope stoppage at exit
Blockage at envelope exit, This error is generated if the

inserting failure, skewing, exit detector is covered
longer than 300 ms.
slippage, exit blockage.

envelope or document
transport from insert area to
closer sensor would take
too long. Longer than the
time that meets 1200 flanks
(approx. 600 mm).
9
063.1 Service Guide
Error handling franking machine

After pressing the i button in an error message screen, the display can show an error code.
The error format for franking machine errors is as follows: FRM-XXX-YYY. The inserter messages are explained
in Error handling inserter on page 164. XXX is an abbreviation that indicates a specific machine part. The following
machine areas/prefixes apply:
XXX
Explanation
Reference
COM
Communication
Communication errors (COM) on

page 188
EX
External
External errors (EX) on page 188
INF
insert'n Frank / insert'n Mail
insert'n Frank / insert'n Mail errors

(INF) on page 189
LIC
License
License errors (LIC) on page 195
SW
Cover switches
Cover switch errors (SW) on page

195
187
Communication errors (COM)

Error
Message
Cause
Information
FRM-COM- 920
No communication with
franking machine
Due to a time out INF determined that communication with the FM has
dropped. Caused by an internal problem at the FM or
by disconnecting the serial
cable. Make sure the cable
is connected and restart the
job from the IN. If this fails,
switch off/on the FM or the
whole system.
At changing DS+MS job

settings (for which information from FM is needed), job
info or starting DS+MS job.
In job edit, after reset: continue the job edit menu. The
fields you cannot adjust and
knobs that belong to these
fields are grey. You can
only select pass through.
FRM-COM- 921
Communication failure with Indicates that the FM won't When pressing start key.
accept commands and/or
franking machine
data from INF. Just wait and
try to start the job again or
switch off/on the FM.
FRM-COM- 922
When pressing start key.

Communication failure with Due to some fatal error
conditions, communication
franking machine
with the FM has dropped in
Alayer. Try to start the job
again or switch off/on the
FM or the whole system.
FRM-COM- 923

franking machine
Tlayer. Try to start the job
FRM-COM- 924

franking machine
Dlayer. Try to start the job
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063.1 Service Guide
External errors (EX)
188
Error
Message
Cause
Information
FRM-EX1- 120
Envelope stoppage
This error is raised when an During run
between inserter and frank- envelope is not franked
ing machine
within X seconds after leaving the inserter. The X is
system and configuration
dependent. The envelope
might not be franked by the
FM.
insert'n Frank / insert'n Mail errors (INF)

Error
Message
Cause
Information
FRM-INF- 000
Auto clean on franking ma- Notification from the FM that When pressing start key.
chine in progress
the Auto Clean Cycle will be
started very soon.
FRM-INF- 001
Franking machine not ready At the FM is currently a dia- When pressing start key.
for franking interface
log displayed as a result of
an error (condition) that occurred while INF was not
executing a job on the FM.
Probably the FM was used
stand alone. Look at the FM
user interface.
FRM-INF- 002
Auto clean on franking ma- Notification from INF that When pressing start key.
the Auto Clean Cycle has
chine is finished
been completed and the
franking process will be resumed automatically.
FRM-INF- 003
Sealing on advanced feeder An attempt is made to start When pressing start key.
of franking machine is selec- an FM job with sealing on
ted
advanced feeder selected.
The user can only solve this

by modifying the FM job
(disable sealing) or modifying the IN job.
Franking machine already
started
The FM cannot be started

as it is already running.
063.1 Service Guide
FRM-INF- 200
Probably the user started

the FM manually or the FM
was not stopped in the previous job. If not, switch
off/on the FM.
FRM-INF- 201
Franking machine stopped This error is raised when

the user pressed the 'Stop'
via start/ stop key
button on the FM during a
run resulting in an emergency stop. The last envelopes(s) that left the franking
machine might not be
franked.
FRM-INF- 202
User PIN code required at The FM has popped up a When pressing start key.
franking machine
dialog to enter the user PIN
code. Job execution will be
blocked until the correct PIN
code has been entered.
189
FRM-INF- 203

Department PIN code re- The FM job selected required at franking machine quires a department PIN
code. INF does not support
this feature. Job execution
is blocked. Either the PIN
code has to be removed or
another FM job has to be
selected.
FRM-INF- 204
Wrong PIN code entered on The user has entered the When pressing start key.
wrong PIN code and the FM
franking machine
will go into 'sleep' mode.
Job execution is blocked.
FRM-INF- 205
User action required at

franking machine
FRM-INF- 206
The franking machine is in An attempt is made to ex- When pressing start key.
ecute a job while the FM is
supervisor mode
in Supervisor mode. Exit
Supervisor mode at the FM
and try to start the job
again.
FRM-INF- 207
ZIP zone required at frank- The FM has popped up a When pressing start key.
dialog to enter the ZIP
ing machine
Zone. Job execution will be
blocked until a ZIP Zone
has been entered.
FRM-INF- 208
Franking machine job selec- Franking interface software

does not support this feated includes correction
ture. Switch off correction
mode
mode or select another
franking machine job
FRM-INF- 209
Franking machine stopped The user has aborted the

franking cycle by pressing
via escape key
'ESCAPE' at the FM. The
job will be aborted.
FRM-INF- 210
Franking machine is in
stand alone mode
FRM-INF- 300
Communication failure with A time-out occurred when During run.

franking machine
attempting to wake up the
FM from sleep/stand-by
mode. The FM did not wake
up in time. Try to start the
job again or switch off/on
the FM.
FRM-INF- 301
Communication failure with Due to an unsupported error When pressing start key.
franking machine
condition the FM refuses to
start. The user has to try to
start the job from the IN
again. If this fails switch the
FM on/off.
9
063.1 Service Guide
190
User action required at

franking machine.
See franking machine for

more details.
The FM is being used 'stand

alone'. As a result INF cannot gain control over the
FM.
FRM-INF- 302
An internal error occurred Due to an unsupported error During run or pressing start
which blocks job execution INF is unable to stop the
key.
FM. Switch off/on the FM.
FRM-INF- 303
Communication failure with Due to an unsupported error During run.

the FM did not complete the
franking machine
starting sequence in time.
Try to start the job again or
FRM-INF- 304
The franking machine is in INF is not able to configure When pressing start key.
the FM as an error has ocerror mode
curred that has not yet been
solved and is not specified.
Please check the FM user
interface for any message
and close any covers. Otherwise switch off/ on the FM.
FRM-INF- 305
The franking machine is in INF is not able to configure When pressing start key.
busy mode
the FM as the FM is busy
for some unknown reason.
Please wait a while, otherwise switch off/on the FM.
FRM-INF- 305
An internal error occurred For some reason the FM is When pressing start key.
which blocks job execution busy and won't accept
commands from INF. Possibly the FM was manually
started by the user. Otherwise switch the FM off/ on.
Auto clean on franking ma- Notification from INF that When pressing start key.
the Auto Clean Cycle takes
chine time out
more time than expected.
Either the user wait until the
FM has actually finished
Auto Clean or switch the FM
off/ on.
FRM-INF- 307
No active rate table
No active rate table, prob- When pressing start key.

ably Base only, activate rate
table.
FRM-INF- 308
Internal error on franking

machine
The FM decided to execute During run or pressing start

an emergency stop. How- key.
ever, it did not provide any
further information for the
reason. Try to start the job
FM.
FRM-INF- 309
Manual clean of cartridge An attempt to force to clean When pressing start key.
on franking machine failed the cartridge manually
failed. Not user solvable!
Try again.
063.1 Service Guide
FRM-INF- 306
191
FRM-INF- 310
More envelopes have been Possible presence of envel- During run.

franked than sent by the in- opes in FM from previous
job, or envelopes manually
serter system
put onto the FM during the
job.
FRM-INF- 311
Selecting franking machine Unable to select a job at the During run or pressing start
FM due to an unsupported key.
job failed
error. Try to restart the job
FM.
FRM-INF- 312
Selecting franking machine Inserter job is coupled to a

non-existing FM job (the
job failed
specified job ID is empty).
Update the job definition at
the IN or create a job at the
FM.
FRM-INF- 313
Wait position occupied
FRM-INF- 314
Franking machine job selec- An attempt is made to start When pressing start key.
ted includes Dynamic batch an FM job from the IN. The
FM job includes Dynamic
mode
Batch Mode which is not
supported when KEOPS is
in Inserter Mode. This job
is blocked by INF. Either the
user has to switch off Dynamic Batch Mode or has
to select another job.
FRM-INF- 315
The franking value exceeded the 'High value

threshold
A job was started in which When pressing start key.

the franking value exceeded
the 'High value' threshold.
The user has to confirm this
high value at the FM by
either pressing 'OK' or 'ESCAPE'.
FRM-INF- 315
Weight exceeds limit
Check weight values in job When pressing start key.

settings.
FRM-INF- 316
Envelope measures
Invalid envelope measure

for PPC management.
9
063.1 Service Guide
192
At changing DS+MS job

settings (for which information from FM is needed),
starting DS+MS job. In job
edit, after reset: continue
the job edit menu. The fields
you cannot adjust and
knobs that belong to these
fields are grey. You can
only select pass through.
INF received data for the

next envelope while the
current envelope has not
yet left the waiting position.
Restart the job.
FRM-INF- 317
An internal error occurred Concerns incorrect set up When pressing start key.
which blocks job execution of the option. An attempt
was made to set the franking mode to an invalid or no
longer supported mode. As
a result the current franking
mode is retained. Probably
caused by incompatible
software versions of Inserter
and INF module.
FRM-INF- 318
Sealing on advanced feeder An attempt is made to start

of franking machine is selec- an FM job with sealing on
ted
the MMF/AF selected. This
can be overruled through
the service menu setting.
See "Sealing on franking
machine on page 41".
FRM-INF- 900
Internal error on franking

machine
It is recommended to seal
with the inserter. This warning is generated when
pressing the start key.
At the FM an error has oc- During run or pressing start

curred that permanently
key.
blocks execution of the current run. The user has to
look at the UI of the FM for
more details. Best case, the
job can be started again
after resolving the problem.
Worst case the FM has to
be switched off/on.
Error or warning on franking At the FM an error has oc- During run or pressing start
machine
curred that temporarily
key.
blocks execution of the current run. The user has to
look at the UI of the FM for
more details. After solving
the problem, the run will be
resumed automatically.
FRM-INF- 902
Communication failure with INF received incorrect envel- When pressing start key.
ope data (unknown hopper
franking machine
or invalid hopper data). Remove any envelopes from
the system and try to start
the job again.
FRM-INF- 903
Communication failure with INF received incorrect envel- When pressing start key.
ope data (unknown thickfranking machine
ness or invalid thickness
data). Remove any envelopes from the system and
try to start the job again.
FRM-INF- 904
An internal error occurred Unable to make some set- During run.

which blocks job execution tings at the FM due to an
unsupported error. Try to
restart the job again or
063.1 Service Guide
FRM-INF- 901
193
FRM-INF- 905
An internal error occurred Unable to retrieve settings During run.

which blocks job execution from the FM due to an unsupported error. Try to restart the job again or switch
off/on the FM.
FRM-INF- 906

An internal error occurred Unable to configure the
which blocks job execution 'Base' (FM) due to an unsupported error. Try to restart
the job again or switch
off/on the FM.
FRM-INF- 907
During run or pressing start

An internal error occurred Unable to configure the
which blocks job execution 'Advanced Feeder' (AF) due key.
to an unsupported error. Try
to restart the job again or
FRM-INF- 908

Internal failure on franking Unable to configure the
'Dynamic Scale' (DS) due
machine
to an unsupported error. Try
to restart the job again or
FRM-INF- 909
Communication failure with The FM did not complete When pressing start key.
the stop sequence in time.
franking machine
The FM might have to be
switched off/on in order to
continue with another job.
FRM-INF- 910
Communication failure with During job execution the FM When pressing start key.
terminated the job unexpecfranking machine
tedly for some unknown
reason. Try to restart the job
FM.
FRM-INF- 911
INF received an envelope When pressing start key.

from the IN but the data for
that envelope was either
lost or never delivered to
INF. INF is unable to recover from this situation. Remove the envelope from the
waiting position and start
the job again.
FRM-INF- 912
Unknown envelope detected
INF has detected a physical When pressing start key.

envelop at the wait position,
but did not receive any data
for it. The envelope (if any)
has to be removed.
FRM-INF- 913
Unknown envelope detected
INF has detected a physical When pressing start key.

envelop at the wait position,
but was not notified about
its arrival. The envelope (if
any) has to be removed.
9
063.1 Service Guide
194
FRM-INF- 914
An internal error occurred INF is busy and cannot ac- When pressing start key.
which blocks job execution cept any commands. An attempt was made to change
settings while INF is busy.
Internal error, not user solvable. Just try again later and
ultimately switch off/on the
whole system.
FRM-INF- 915
FIFO Overflow
FIFO Overflow for PPC

variable mode.
FRM-INF- 916
Rate calculation
Rate calculation failure.
Cause
Information
License errors (LIC)

Error
Message
FRM-LIC- 300
An internal error occurred Concerns incorrect set up When pressing start key.
which blocks job execution of the option. The INF level
is set to
INF_LEVEL_NO_INF.
Probably caused by incompatible software versions of
Inserter and INF module.
Internal error, not user solvable.
9
063.1 Service Guide
Cover switch errors (SW)

Error
Message
Cause
Information
FRM-SW5- 200
Cover open on franking

machine
During run or pressing start

Franking machine cover
open, cover switches defect key.
or loose? Close the cover.
This error is only generated
when the cover switch is
activated. It does not register if the cover is open or
closed.
195

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6204 Series

Electrical description ....................................................................................138

A0004538 Assy Display blanco

Display board + Keyboard

063.1 Service Guide

Motor relay board

2992001S (expanded) (optional)

Wiring display board

063.1 Service Guide

Motor relay board

Wiring motor relay board

063.1 Service Guide

Wiring connection board (regular)

b. Connection board, expanded (optional)

Wiring connection board (expanded)

Communication board (optional)

Testpoints and LEDs on the communication board

Franking interface (FIF)

Flash write in progress indication

2989408R (Reading head)

2994532D (Without communication board)

2994532D (Without communication board)

Testpoints and LEDs on the main board

OMR window oscilloscope

Main pulsedisc signal

Depends on paper thickness

DFC out feeder 1

Depends on paper thickness

DFC out feeder 3

Depends on paper thickness

DFC out feeder 2

Depends on paper reflection Analog OMR signal

Main pulsedisc indication

Folding table 1 indication

Folding table 2 indication

Collator pulsedisc indication

Flash write in progress indication

Preventive maintenance ................................................................................156

063.1 Service Guide

160k Service visit

Rubber paper puller

Rubber paper puller

Rubber paper puller

Rubber paper puller

Feed roller kit 3 station expert

Feed roller kit 2 station expert

(*) Depending on the configuration

063.1 Service Guide

Check with the operator if there are any problems detected.

Check the alignment of the document hoppers.

Replace all paper pullers of the feeders.

Clean the sealing and closing area of the inserter.

500k Service visit

Jogger roller Oring

Jogger roller Oring

Collating belt set Collating belt set 30

Check with the operator if there are any problems detected.

Clean the rollers of the vertical track.

Check the tension of the driving belts.

Slightly lubricate the bearings.

Clean the rollers per feeder.

Replace the O-rings of the jogger rollers.

Clean the rollers of the envelope track.

Check if the rollers are still clicked correctly.