PS1000 Maintenance Guide

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 CONTENTS
....................................................................................................................................................................... 1
PC Chassis Settings.................................................................................................................................... 3
Bios Settings................................................................................................................................................................ 3
Cable Architecture Overview....................................................................................................................... 4
PCB Connection Mappings......................................................................................................................... 5
Transport Control Master (TCM) Node 1................................................................................................................5
Node 2........................................................................................................................................................................6
Node 3........................................................................................................................................................................7
Node 4........................................................................................................................................................................8
Node 5........................................................................................................................................................................9
Node 6.......................................................................................................................................................................10
Front ICC Assy.........................................................................................................................................................11
Rear ICC Assy.........................................................................................................................................................12
Platen Setup............................................................................................................................................... 13
Hopper Platen..........................................................................................................................................................13
Stacker 1 Platen......................................................................................................................................................13
Pick Arm Setup........................................................................................................................................... 14
Pick Arm angle.........................................................................................................................................................14
Pick Arm Detector Setup........................................................................................................................................14
Front Image Head Assy.............................................................................................................................. 17
Removal & Replacement........................................................................................................................................17
Replacing Front CIS head Assembly....................................................................................................................32
Front Image Head gap setup.................................................................................................................................32
Rear Image Head gap setup........................................................................................................................................32
Imaging Full Width Roller Check...........................................................................................................................32
Sheet Detectors.......................................................................................................................................... 33
Front View................................................................................................................................................................. 33
Rear View.................................................................................................................................................................34
Sheet Detector Calibration........................................................................................................................ 35
Sorter (Flipper)........................................................................................................................................... 35
Sorter Module Replacement..................................................................................................................................35
Calibrating and configuring the Sorter module....................................................................................................41
Module Identification (Rear View)............................................................................................................. 42

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PC Chassis Settings
Bios Settings

Check the mainboard BIOS:

Set Boot > Delay Time to 10 seconds
Set CPU Fan (H/W Monitor > CPU_FAN1 & 2 Setting) to Automatic
Set H/W Monitor > CPU_FAN1 & 2 Setting > Target Fan Speed to Level 9
Set Chassis Fan (H/W Monitor > CHA_FAN1 & 2 Setting) to Full On
Set Over-Temperature Alarm (H/W Monitor > Over Temperature Protection) to Enabled

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CABLE ARCHITECTURE OVERVIEW

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PCB CONNECTION MAPPINGS

Transport Control Master (TCM) Node 1

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Node 2

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Node 3

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Node 4

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Node 5

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Node 6

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Front ICC Assy

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Rear ICC Assy

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PLATEN SETUP

Hopper Platen
Check the Hopper Platen is 90 degrees to the front plate, if it is not then:
Adjusting one of the two screws, and using a Try Square, set platen to 90 degrees to the Front
plate
Hold the screw in position and the tighten locknut making sure the screw doesn’t move.
Recheck the set angle
If this cannot be achieved then remove paint from both support forks, top and underside for
each platen (Note: future units should make allowance for this)
Wind the other screw down by hand until it just touches, tapping the platen with a finger listen
for any rattle or buzz, continue adjusting screw gently by hand until this is eliminated.
Hold screw in position and the tighten locknut
Ensure that each platen does not rattle or buzz when tapped
Remove and refit each platen to test this further (Note: at the time of writing each platen is
dedicated to a particular machine and its position, furthermore it should have a label on the
underside indicating this)

Stacker 1 Platen
Check the Stacker Platen is 90 degrees to the front plate, if it is not then:
Adjusting one of the two screws, and using a Engineers Square, set platen to 90 degrees to the
Front plate
Hold the screw in position and the tighten locknut making sure the screw doesn’t move.
Recheck the set angle
If this cannot be achieved then remove paint from both support forks, top and underside for
each platen (Note: future units should make allowance for this)
Wind the other screw down by hand until it just touches, tapping the platen with a finger listen
for any rattle or buzz, continue adjusting screw gently by hand until this is eliminated.
Hold screw in position and the tighten locknut
Ensure that each platen does not rattle or buzz when tapped
Remove and refit each platen to test this further

Note: each platen is dedicated to a particular machine and its position, furthermore it
should have a label on the underside indicating this.

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PICK ARM SETUP

Pick Arm angle

Set Pick Arm ‘toe in’ to be 1.5 degrees, use production setting gauge PT457

or

Loosening Pick Motor module mounting screws and sliding module fully towards the right
towards the closest outside edge.

Pick Arm Detector Setup

Adjust the Pick Arm Up Detector:

Using Diagnostics set the input hopper platen so that the Pick arm wheel are not contact it, this
can be done using the “Go to Clear Position” Button as below

Adjust the base plate of the Pick Arm Down detector (the one on the left) so the sensor and
LED are aligned on the centre of the slot of the Pick Arm Flag.

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 Pick Arm Up

Pick Arm Down

Pick Arm Flag

Now raise the Input Hopper platen to the Pick Position (the height the platen will be when
picking sheets) using the “Go To Pick Arm Up (Pick) Position” button, as seen below.

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Once the Input Hopper Platen has reached this position both the Pick Arm Up Detector and the
Pick Arm Down Detector should be on, as seen above!

Place a metal ruler on the platen against the Pick wheel and check to see if the if height is
aligned with the middle of the Cliff Edge.

Centre of the
Cliff

Cliff

If the Input Hopper Platen is too high you may get more double feeds! To reduce the height of
the platen, move the Pick Arm Up Detector base plate (the one on the right) slightly closer to
the Pick Arm Down Detector.

Now check the new height by pressing the “Go to Clear Position” button so the platen drops and
then click the “Go To Pick Arm Up (Pick) Position” button and recheck the height.

If the Input Hopper Platen it is too low, move the Pick Arm Up Detector (on the right) further
away from the Pick Arm Down Detector and then recheck.

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FRONT IMAGE HEAD ASSY

Removal & Replacement

Introduction
These instructions should only be followed by a fully trained Engineer. The Assembly being
replaced is very expensive and fragile so must be handled and stored carefully. Before
attempting any of the stages, read the instructions fully. When fitting the new CIS Assembly,
you will be following these instructions in reverse, so you may wish to make notes or take
additional photos for your own references. Should any of the steps in this document not make
sense contact DRS support to seek clarification.

Tools Required
Torx 10 Driver
Torx 20 driver
Flat blade Screwdriver
Side Cutters

Removing the CIS Head Assy

Before attempting the removal of the CIS Head Assy, disconnect the scanner from the main
supply and unplug all cables i.e. Mice, Keyboard, Monitor and network.
Now remove the rear large grey cover using a Torx 20 screwdriver so you have access to the
inside of the back of the scanner.

1. Pull out the CIS front head cover in the direction shown in Fig.1

Fig.1

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2. Unscrew the three Torx 10 screws shown in Fig.2

Fig.2

3. Unscrew the two Torx 10 screws as shown in Fig.3

Fig.3

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4. After all the screws have been removed, gently remove the grey cover away from the
CIS assembly being very careful not to break the earth cable as shown in Fig.4

Fig.4

5. Now pull off the earth cable see Fig.5, this will then allow the grey CIS Head cover to
be removed completely.

Fig.5

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 6. This is how it should look like with the grey cover completely removed, see Fig.6

Fig.6

7. Now remove the front black target plate which is indicated by the green arrow. To do
this you will need to remove the three Torx 10 screws indicated by the orange arrows.
See Fig.7

Fig.7

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8. Once the three Torx 10 screws are removed the black target plate will easily come
off, so please be careful not to drop this on the glass CIS head by holding the plate as
you remove the screws.

Fig.8

9. Remove the 6mm Torx 10 screw shown in Fig.9 (Green arrow). Then remove the
8mm Torx 10 screw shown as the (Yellow arrow). Note: These screws must go back
in the same order they came out, or else the CIS head will not engage

Fig.9

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10. After the removal of the plate it should look like Fig.10

Fig.10

11. From the back of the scanner locate the white ferrite and cut the black-tie wraps as
indicated on Fig.11

Fig.11

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12. Insert the black ferrite key into the two slots as shown on fig.12 to release the ferrite
from the cable. Note - if you don’t have one of these keys use a small flat blade screw
driver to release this ferrite.

Fig.12

13. Remove the two Torx screws indicated with green arrows, this will then give you
access to the black and white CAN cable shown with the orange arrow in Fig.13

Fig.13

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 14. Once you gain access, unscrew the CAN header with a flat blade as seen on Fig.14
Note: Be careful and unscrew each screw 1 turns at a time before both screws are released.

Fig.14

15. Using a small flat blade screwdriver press the latch to release the encoder cable and
then remove as shown in Fig.15

Fig.15

16. Using a Torx 10 driver, remove the earth cable that is linked to the front CIS head
assembly. See Fig.16

Fig.16

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17. Cut the cable ties indicated by the green arrows and then trace the power cable as
indicated by the yellow arrows in Fig.17. This cable will need to be unplugged.
Be very careful not to cut any of the cables!!

Fig.17

18. Before you can unplug the power cable you will need to remove the PC Cable Guard.
To do this remove the two Torx 10 screws indicated by the green arrows. Once you
have removed the cover, unclip the power cable you traced for the front CIS head
assembly. See Fig.18

Fig.18

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19. Now feed the power cable (yellow arrow) through the hole (green arrow) in the cable
management plate. See Fig.19

Fig.19

20. Push the green tab (IN), to release the PCIe cable connector indicated with the green
arrow (See Fig.20). While keeping the green tab in the (IN) position, pull in the
direction indicated by the yellow arrow in Fig.20.

Fig.20

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21. Now come around to the front of the scanner and disconnect the black ethernet cable
from the front CIS head assembly. See Fig.21

Fig.21

22. Now cut the black cable ties as shown on Fig.22 to release the ethernet cable.
Be very careful not to cut the cable!!

Fig.22

23. Now coil up the ethernet cable and move to one side. See Fig.23

Fig.23

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24. Pull the black heat shrink with all the cables in the direction of the green arrow, so it is
now off centre. Now hold the front head thumb latch and push in the direction
indicated by the yellow arrow. See Fig.24

Fig.24

25. Keep pushing towards the direction indicated by the yellow arrows, so that the thumb
latch spring has passed the metal bracket indicated with the green arrow. See Fig.25

Fig.25

26. Push the thumb latch spring (in the direction of the yellow arrow), up and over the
metal tab as indicated with the green arrow. See Fig.26

Fig.26

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27. Loosen (slightly) the two Torx 10 screws indicated by the green arrows but Do Not
Remove. Then undo the black grub screw using a 2.5mm Hex key as indicated with
the yellow arrow but again Do Not Remove. See Fig.27

Fig.27

28. Place some bubble wrap under the glass head to protect the glass from being
damaged as indicated by the yellow arrows. Pull and lift the front CIS head assembly
in the direction indicated by the green arrows. Then gently pull the assembly away in
the direction indicated with the blue arrows. The red arrow shows the point the CIS
head will separate from the Scanner. See Fig.28

Fig.28

29. Now place the CIS head assembly gently on the bubble wrap. See Fig.29

Fig.29

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30. Now go around to the back of the scanner and cut the black cable tie as indicated
with the green arrow, making sure you don’t cut any cables! Now straighten all five
cables as seen on Fig.30

Fig.30

31. Now gather all the five cables together and feed them through the hole towards the
indicated with green arrows whilst gently pulling the CIS head assembly towards the
indicated yellow arrow. Note. This is best done with two people! See Fig.31

Fig.31

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32. Continue gently feeding through all five cables for the CIS head assembly through
one by one. Do not remove the ethernet cable indicated with a red arrow as this is
needed for the new assembly. See Fig.32

Fig.32

33. The last cable that should be feed through the hole is the PCIe connector as shown in
Fig.33

Fig.33

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 34. The image below shows what the front CIS head assembly will look like when it has
been successfully removed from the scanner. See Fig.34

Fig.34

Replacing Front CIS head Assembly

Installing a new CIS head assembly should be carried out by following these instructions in
reverse order. Once the new assembly is installed, do not put the covers back on as there is a
setup, calibration and test set of instructions that must be carried out first. These instructions
will be sent separately.

Front Image Head gap setup

Check Image head assembly stability, and gap

When the head is fully engaged check to make the sure Upper head assembly does not move
in any direction other than in or out.
Set gap of the Front image head to 0.9mm to 1.1mm

Rear Image Head gap setup

Set gap of Lower image head to 0.9mm to 1.1mm

Align the "Lower CIS Head Cover - Black Target Assembly (AN5261)" with the front image head
to close the gap to less than 0.1mm, which is the thickness of a PS Series Test Sheet.

Imaging Full Width Roller Check

Check and / or set the imaging full width roller assemblies to be 90 degrees to the face of the
Front plate. Use setting gauge PT460.

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SHEET DETECTORS

Front View

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Rear View

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SHEET DETECTOR CALIBRATION

1. Calibrate all detectors:

a. Calibrate
b. Check they all successfully complete
c. Ensure all detector threshold values are within acceptable limits as specified in Diagnostics
d. Save all sheet detector settings

2. Advanced Calibration – This should only be carried out if a sensor/LED or cable is replaced or
realigned
a. Select detector effected
b. Click Full Threshold Range Box
c. Select Calibrate
d. Ensure all detector threshold values are within acceptable limits as specified in Diagnostics
e. Save all sheet detector settings.

SORTER (FLIPPER)

Sorter Module Replacement

Tools Required 
Torx 10 Driver 
Torx 20 driver 
Side Cutters 

Removing the Sorter Module (AN5104)

Before attempting the removal of the Sorter Module Assembly, disconnect the scanner from the main supply and
unplug all cables i.e. Mice, Keyboard, Monitor and network. 
Now remove the rear large grey cover using a Torx 20 screwdriver so you have access to the inside of the back of
the scanner.  

1. Remove the output cover by removing all 5 pan Torx screws. See fig.1

Fig.1
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2. Now the cover has been removed it will now reveal the sorter module see Fig.2

Fig.2

3. Now go around the back of the scanner and locate the sorter motor connector which is connected to
node 3, the connector will look like the one indicated by the green arrow shown in Fig 3.

Fig.3

4. Press the top of the clip down towards the housing shown by the amber arrow and pull the two
connectors apart as shown by the green arrow in fig 4.

Fig.4

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5. Now cut any cable ties holding the sorter motor cable in the loom shown by the green arrow. The
amber arrow shows all the cable ties removed in fig 5.

Fig.5

6. You can now start to push the cable from the back of the machine, through the hole in the plate. In the
direction shown by the green arrow. The amber arrow shows the view from the FRONT of the scanner
shown in fig 6.

Fig.6

7. The cable should now be fully through as shown in Fig.7

Fig.7

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8. Now remove the encoder cable from the sorter motor indicated by the amber arrow. The black
connector has a clip which needs to be pressed in at the same time as you pull the cable out indicated
by the green arrow. See Fig.8

Fig.8

9. Now both Encoder and power cable connector’s have been disconnected. you can lay them down as
shown see Fig.9

Fig.9

10. Now remove the 4 Torx screws shown with the green arrows in Fig.10.
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 Fig.10

11. Now remove the single pan Torx screw shown by the green arrow. Note: you will need to support the
module as shown with the amber arrow Fig.11. Be aware there are sensor and LED cables which can
catch on the sorter module when you remove it, so be careful NOT to pull any cables out of there
sockets.

Fig.11

12. Now the sorter module is fully removed See fig. 12.

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 Fig.12

13. You can now fit the new sorter module. Installing a new sorter module assembly should be carried out
by following these instructions in reverse order.

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Calibrating and configuring the Sorter module

1. Calibrating the Sorter:

a. Using Diagnostics
b. Click “Calibrate Flip Range”, check the result of calibration on the Calibration State line, if
successful, click Save to save the calibration setting.
c. If calibration fails, adjust the grub screws of the frictional dampener. These typically have to be
tightened so their head is half way into the dampener.

2. Check / adjust the Upper Position:

a. Raise the Sorter using the “Go Up” button
b. If the Sorter does not align with where router wheel and pinch rocker meet:
i. Open the Sorter properties
ii. Change the FlipperUpPosition (higher the value, the higher the Sorter)
iii. Save setting using Ok.
iv. Lower the Sorter using Go Down button and repeat from a until you are happy
with the Sorter position when raised.

3. Check / adjust the Lower Position:

a. Lower the Sorter using Go Down button
b. If the Sorter is either above the paper path or too low below the paper path :
i. Open the Sorter properties
ii. Change the FlipperDownPosition (Lower the value, the lower the Sorter)
iii. Save setting using Ok.
c. Raise the Sorter using Go Up button and repeat from a until you are happy with the Sorter
position when down.

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MODULE IDENTIFICATION (REAR VIEW)

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