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IC 1000/IC 1825 and NDP 1000-4X/NDP1825-4X Imaging Module Installation and Servicing Guide(2983 7986204)

This Product Information Announcement announces a revision of this the IC 1000/IC 1825 and NDP 1000-4X/NDP1825-4X Imaging Module Installation and Servicing Guide, dated December 1998.

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iii through iv iii through iv51 through 516 51 through 516A1 through A2 A1 through A2

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United States customers, call Unisys Direct at 1-800-448-1424.

Customers outside the United States, contact your Unisys sales office.

Unisys personnel, order through the electronic Book Store at http://iwww.bookstore.unisys.com.

Comments about documentation can be sent through e-mail to [email protected].

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Announcement only: Announcement and attachments: System: IC 1000/IC 1825 andNDP 1000-4X/NDP1825-4X Imaging Module

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Installation and Servicing Guide

IC 1000/IC 1825ANDNDP 1000-4X/NDP1825-4X IMAGINGMODULE

Unisys Proprietary

This document is confidential and proprietary to Unisys Corporation. It is not to be used,reproduced, or disclosed outside Unisys without the written consent of UnisysCorporation. The information in this document is furnished for use by Unisys supportpersonnel in servicing customers equipment, or by a customer under a license

agreement with Unisys.

This document is the property of Unisys. Upon termination of customers license to thismaterial, it should be returned to Unisys Corporation, Global Customer Services, PO Box500, Blue Bell, PA 19424.

LIMITED RIGHTS - This document is technical data provided to the U.S. Governmentwith limited rights pursuant to DFARS 252.2277013 and 252.2117015/FAR 52.22714& 52.22719.

Copyright 1998 Unisys Corporation.Unpublished Material - All rights reserved.

December 1998

Printed in USAPriced Item 2983 7986204


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Installation and ServicingGuide

IC 1000/IC 1825ANDNDP 1000-4X/NDP1825-4X IMAGING MODULE

Copyright 1998 Unisys Corporation.All rights reserved.Unisys is a registered trademark of Unisys Corporation.

December 1998

Printed in USAPriced Item 2983 7986204


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The names, places, and/or events used in this publication are not intended to correspond to anyindividual, group, or association existing, living, or otherwise. Any similarity or likeness of the names,places, and/or events with the names of any individual, living or otherwise, or that of any group orassociation is purely coincidental and unintentional.

NO WARRANTIES OF ANY NATURE ARE EXTENDED BY THIS DOCUMENT. Any product or relatedinformation described herein is only furnished pursuant and subject to the terms and conditions of aduly executed agreement to purchase or lease equipment or to license software. The only warrantiesmade by Unisys, if any, with respect to the products described in this document are set forth in suchagreement. Unisys cannot accept any financial or other responsibility that may be the result of youruse of the information in this document or software material, including direct, special, or consequential

damages.

You should be very careful to ensure that the use of this information and/or software material complieswith the laws, rules, and regulations of the jurisdictions with respect to which it is used.

The information contained herein is subject to change without notice. Revisions may be issued toadvise of such changes and/or additions.

RESTRICTED Use, reproduction, or disclosure is restricted by DFARS 252.2277013 and 252.2117015/FAR 52.22714 & 52.227-19 for commercial computer software.

Correspondence regarding this publication should be forwarded to Unisys Corporation by addressingremarks to Product Information, Unisys Corporation, 41100 Plymouth Road, Plymouth, MI 48170U.S.A.

Comments about documentation can also be sent through e-mail to [email protected].

Unisys is a registered trademark of Unisys Corporation.All other terms mentioned in this document that are known to be trademarks or service marks havebeen appropriately capitalized. Unisys Corporation cannot attest to the accuracy of this information.Use of a term in this document should not be regarded as affecting the validity of any trademark orservice mark.


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2983 7986204 iii

Page Status

Page Issue

iii 204iv Blankv through xi 203xii Blankxiii 203xiv Blankxv through xviii 20311 through 17 20318 Blank21 through 290 20331 through 34 20341 through 477 203478 Blank51 through 516 2045-17 through 5-51 203552 BlankA-1 through A-2 204A3 through A145 203A146 through A147 204

Glossary1 through 6 203Index1 through 11 203Index12 Blank


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2983 7986203 Unisys Proprietary - Class B v

Contents

About This Guide ....................................................................................... xv

Section 1. Operation and Components

IC 1000/IC 1825 Imaging Module ........................................ 11Operation ................................................................ 11Imaging Module Interfaces ........................................ 12

Imaging Module Components .................................... 14NDP 1000-4X/NDP 1825-4X Imaging Module ..................... 15

Operation ................................................................ 15Imaging Module Components .................................... 16Image Module Interfaces ........................................... 17

Section 2. Imaging Module Installation on a DocumentProcessor

Document Processor Circuit Breaker Upgrade ..................... 22Unpacking the Imaging Module ............................................. 26Preparing the Document Processor ...................................... 27

Installing the Imaging Module ............................................... 210Leveling the Machine ............................................................. 213Installing Microfilmer Drive Transfer Components ................ 215Drive Installation - TDC Microfilmer ...................................... 216Drive Installation - Unisys Microfilmer ................................... 216Microfilmer Air Hose Relocation ............................................ 216Drive Installation - No Microfilmer ......................................... 217

Procedure A ............................................................ 217Procedure B ............................................................ 219

Cooling Change Installation For the NDP 1000-4X/ NDP1825-4X Imaging Module .................................................. 220

Reject Pocket Assembly ........................................................ 224Top Cover Trim Installation ................................................... 225

Area 1 ..................................................................... 225NIE/MJE .................................................................. 225High Speed Encoder Module ..................................... 226Unisys Microfilmer .................................................... 226TDC Microfilmer ....................................................... 226

Installing Document Processor Interface Harnesses andLogic With an IC 1000/IC 1825 Imaging Module ............. 227


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Installing Document Processor Interface Harnesses andLogic With an NDP 1000-4X/NDP 1825-4X ImagingModule ............................................................................... 232

Circuit Breaker Installation on a Dual Imaging Module ......... 236

Unpacking the U4 or JPEG Electronics Gate and CCITTGate .................................................................................... 239

U4 Electronics Gate .................................................. 239JPEG Electronics Gate .............................................. 240

Installing the U4 Electronics Gate .......................................... 241Installing the U4 Electronics Gate PCBAs .............................. 249Connecting the U4 Image Cables .......................................... 251

Secondary AC Harness ............................................. 251IM Fan Harness ........................................................ 25324-Volt Bias Harness ................................................ 254Document Processor Interface Cable ......................... 255Five-Volt Power Supply Ground Cable ......................... 256Five-Volt DC Sense Harness ....................................... 257

Image Lift Power Cable ............................................. 25815-Volt Harness ........................................................ 259Five-Volt Power Supply Cables ................................... 260Video Cables ............................................................ 261Lamp Power Supply Interface Cable ........................... 263

Installing the JPEG and CCITT Electronics Gate .................... 264Connecting the External JPEG Image Cables ........................ 275

Lamp Controller Interface (DTI) Cable ......................... 276Lamp Controller (Auxiliary 15-Volt) Power Cable .......... 276Secondary AC Supply Harness .................................. 27615-Volt Camera Harness ........................................... 278Document Processor Interface Cable ......................... 27824-Volt Sense Harness .............................................. 279

Logic Ground Cable .................................................. 280POL Fiber Optic Cable ............................................... 280CAR Data Cable ........................................................ 281Video Cables ............................................................ 281

Installing Dual Imaging Module Interface Cables .................. 282Installing ICS Components ..................................................... 287U4 and JPEG IM Power Up and Check Out ............................ 288Dual IM Power Up and Check Out .......................................... 289

Section 3. IC 1000/IC 1825 Imaging Module Components


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Section 4. Maintaining the IC 1000/IC 1825 ImagingModule

Maintenance Philosophy ........................................................ 41

Field Replacement Modules (FRMs) ...................................... 42Electronics Gate FRMs .............................................. 43Imaging Module FRMs in the Document Processor ...... 43

Imaging Module FRMs Removal and ReplacementProcedures ........................................................................ 44

U4 Cables and Harnesses ......................................... 44JPEG Cables and Harnesses ..................................... 46Camera Box ............................................................ 49Circuit Breakers ....................................................... 413Energy Dump Fan ..................................................... 41415-Volt Power Supply ............................................... 415Image Camera PCBA Assemblies .............................. 419IM Cooling Fan ......................................................... 421Lamp and Enclosure ................................................. 422Lamp Control PCBA .................................................. 425Lamp Cooling Fan .................................................... 427Lamp Power Supply ................................................. 429Power Control PCBA ................................................. 432Shutter Sensor and Actuator ..................................... 433Track Components ................................................... 434

Beam of Lights ................................................ 434Bearing Housing and Shaft Assembly ................ 436Belts ............................................................... 437Cover Interlock Switch ...................................... 438Crown Roller Assembly ..................................... 438

Front Frame and Window Assembly ................... 439Idler Assembly ................................................. 440Front Left Idler Pulley ............................... 440Front Right Idler Pulley ............................. 441

Rear Frame and Window Assembly .................... 442Track Interlock Switch and Actuator .................. 443

U4 Electronics Gate FRMs ..................................................... 444Backplane ............................................................... 444Cables and Harnesses .............................................. 447Card Guide .............................................................. 448Ejector .................................................................... 4495-Volt Power Supply ................................................. 450Fan Filter ................................................................. 452

Fans ....................................................................... 453PCBAs .................................................................... 455

JPEG Electronics Gate FRMs ................................................. 458Backplane ............................................................... 458Cables and Harnesses .............................................. 460Card Guide .............................................................. 461Ejector .................................................................... 4635/15 Volt Power Supply ............................................ 465Fan Filter ................................................................. 467


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Fans ........................................................................ 468PCBAs ..................................................................... 469

Clock PCBA ..................................................... 470Video Interconnect PCBA .................................. 471

Lamp Controller/DTI Interface (LC/DTI I/F)PCBA .......................................................... 471Imaging Module FRMs in the Document Processor ............... 472

Image Button Light ................................................... 472Image Circuit Breaker ............................................... 473Image Interface PCBA ............................................... 474Image Power Line Filter ............................................. 476

Preventive Maintenance ......................................................... 477

Section 5. Maintaining the NDP 1000-4X/ NDP 1825-4XImaging Module

Front Camera Board/Lens Assembly .................................... 52Calibrating the Cameras ........................................................ 55Rear Camera Board/Lens Assembly ..................................... 58Front Camera Head ............................................................... 510Rear Camera Head ................................................................ 514Thermal Sensor ...................................................................... 519Light Sensor Assembly (Front or Rear) .................................. 520Lamp Socket Assembly (Front or Rear) ................................. 523Lamp Cover Interlock Switch ................................................. 526Lamp Control Board ............................................................... 529Logic/Lamp Power Supply ..................................................... 530Camera (Linear) Power Supply (DP 1000, DP 1800 Front

and Rear) ........................................................................... 533

Backplane (DP 1000 and DP 1800) ...................................... 535Power Supply Fan .................................................................. 539Logic Gate Fans ..................................................................... 539Track Components ................................................................. 541

Beam of Lights ......................................................... 542Bearing Housing and Shaft Assembly ......................... 543Belts ....................................................................... 545Cover Interlock Switch .............................................. 547Crown Roller Assembly ............................................. 547Idler Assembly ......................................................... 549

Front Left Idler Pulley ........................................ 549Track Interlock Switch and Actuator ........................... 551

Appendix A. Special Engineering Instructions and Tests andAdjustments

Glossary ....................................................................................................... 1

Index .............................................................................................................. 1


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Figures11. DP 1XXX Document Processor With IC 1XXX Imaging Module .................... 1212. Imaging Module System Interfaces ......................................................... 1313. NDP 1XXX Document Processor With NDP 1000-4X/NDP 1825-4X

Imaging Module (Dual IM) ................................................................... 15

21. Circuit Breaker Housing ......................................................................... 2322. Document Processor Electrical Connections ............................................ 2823. Image Module Shoulder Bolt Connections ................................................ 21124. Bolting and Alignment of 8-Pocket Modules ............................................... 213

25. Timing Belt Installation ........................................................................... 21526. Idler Arm and Pulley Installation .............................................................. 21827. Relocating the Air Outlet Hose (Inside Module Looking Out) ....................... 22028. Relocating the Air Outlet Hose (Outside Module Looking In) ....................... 22129. Detail of Air Flow Diversion Adapter Location ........................................... 222210. Quarter Panel Foam Removal ................................................................. 224211. BOL/Interlock Harness Installation .......................................................... 228212. Breaker Panel Wiring ............................................................................. 229213. Image RFI Filter ..................................................................................... 230214. BOL/Interlock Harness Installation .......................................................... 233215. Breaker Panel Wiring ............................................................................. 237216. Image RFI Filter ..................................................................................... 238217. Electronics Gate and Plenum .................................................................. 240

218. Electronics Gate Mounting Rails .............................................................. 241219. Center Frame Fan Panel ......................................................................... 243220. Fan Panel ............................................................................................. 244221. 5-Volt Power Supply ............................................................................... 246222. Frame Drilling Locations ........................................................................ 247223. Secondary AC Harness Routing .............................................................. 252224. IM Fan Harness Routing ......................................................................... 253225. 24-Volt Bias Harness Routing ................................................................. 254226. Document Processor Interface Cable Routing .......................................... 255227. 5-Volt Power Supply Ground Cable Connection ......................................... 256228. 5-Volt DC Sense Harness Routing ........................................................... 257229. Image Lift Power Cable Routing .............................................................. 258230. 5-Volt Power Supply Cable Connections .................................................. 260

231. Video Cable Routing .............................................................................. 262232. Lamp Power Supply Interface Cable Routing ............................................ 263233. Location of Lamp Controller Interconnect PCBA Interface and Video

Interconnect PCBAs ........................................................................... 265234. AC Line Filter Location ........................................................................... 266235. Correct Position of Bus Bars .................................................................. 267236. JPEG Wiring Diagram ............................................................................. 271237. EMI Ground Strap Locations ................................................................... 273238. Location of External Cable Connectors .................................................... 275


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Figures

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239. JPEG Lamp Controller Power and Interface Cable Routing ......................... 276240. JPEG 15-Volt Camera Power Cable Routing .............................................. 278241. JPEG 24-Volt Bias Harness Routing ......................................................... 279242. NDP 1150 Backplane Connectors ........................................................... 283

243. NDP 1825 Backplane Connectors ........................................................... 284244. NDP 1150 Dual Image Wiring Block Diagram ........................................... 285245. NDP 1825 Dual Image Wiring Block Diagram ........................................... 286

31. Component Locator (Front) ..................................................................... 3132. Component Locator (Rear) ..................................................................... 3233. Track Components ................................................................................ 3234. U4 Electronics Gate PCBA Locator JPEG Electronics Gate PCBA ............... 3335. JPEG Electronics Gate PCBA Locator ...................................................... 34

41. Camera Box .......................................................................................... 4942. Optical Tower Removal .......................................................................... 41043. Energy Dump Fan .................................................................................. 414

44. 15-Volt Power Supply ............................................................................. 41645. Image Camera PCBA Assembly ............................................................... 41946. IM Cooling Fan ...................................................................................... 42147. Lamp and Enclosure .............................................................................. 42248. Lamp Control PCBA ............................................................................... 42549. Lamp Cooling Fan .................................................................................. 427410. Lamp Power Supply ............................................................................... 429411. Power Control PCBA .............................................................................. 432412. Shutter Sensor ...................................................................................... 433413. Track Components ................................................................................ 435414. Belt, Idler, and Tensioner Locations ........................................................ 437415. Front Frame and Window Assembly ......................................................... 439416. Rear Frame and Window Assembly .......................................................... 442

417. Backplane ............................................................................................. 445418. 5-Volt Power Supply ............................................................................... 450419. Image Gate Fans ................................................................................... 453420. Inserting a PCBA ................................................................................... 455421. JPEG Backplane Connectors ................................................................... 459422. JPEG Fans ............................................................................................ 468423. Image Circuit Breaker ............................................................................ 473424. Image Interface PCBA ............................................................................ 475

51. Front Camera Board/Lens Assembly and Camera Head Cable (OverheadView) ................................................................................................ 53

52. Inserting a Pen into the Top Hole of the Camera Frame and Window

Assembly .......................................................................................... 5653. Pulling the Camera Frame and Window Assembly Out ............................... 5754. Rear Camera Head and Cable (Overhead View) ......................................... 5955. Front Camera Head, Cable, and Fiber Optic Cables (Overhead View - Fiber

Optic Cable Covers Removed) ............................................................ 51156. Lamp Cover and Fiber Optic Cable Cover ................................................ 51257. Front Light Sensor Assemblies ................................................................ 51358. Rear Camera Head and Cables (Overhead View - Fiber Optic Cable Covers

Removed) ......................................................................................... 51559. Lamp Cover and Rear Fiber Optic Cable Cover ......................................... 516


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Figures

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510. Rear Light Sensor Assemblies ................................................................ 517511. Lamp Cover and Thermal Sensor ............................................................ 519512. Lamp Cover and Fiber Optic Cable Cover ................................................ 521513. Light Sensor Assembly Connector .......................................................... 522

514. Lamp Cover and Lamp Socket Assemblies .............................................. 524515. Baseplate, Bracket, and Fan ................................................................... 525516. Lamp Cover and Lamp Cover Interlock Switch ......................................... 527517. Bracket ................................................................................................ 528518. Lamp Control Board .............................................................................. 529519. Logic/Lamp Power Supply ..................................................................... 531520. Logic/Lamp Power Supply Connector Identification .................................. 532521. Logic/Lamp Power Supply and Linear Power Supply ................................ 534522. Backplane ............................................................................................ 536523. DP 1000 Backplane Connectors ............................................................. 537524. DP 1825 Backplane Connectors ............................................................. 538525. Logic Gate Fans .................................................................................... 540526. Track Components ................................................................................ 541

527. Beam of Light Pairs ............................................................................... 542528. Bearing Housing and Shaft Assembly and Belts ....................................... 544529. Belt, Idler, and Tensioner Locations ........................................................ 546530. Crown Roller Assembly and Belts ............................................................ 548531. Front Left Idler Pulley and Belt and Tensioner Locations ........................... 550


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Tables21. NIE Power Supply Connection ................................................................. 2822. AC Control Cables ................................................................................. 2923. IM Shoulder Bolt Usage .......................................................................... 21224. PROM and PCBA Minimum Levels ........................................................... 23125. Added AA Gate Backplane Wiring ............................................................ 23126. Added AA Gate Backplane Wiring Changes For Dual IM DL1/DL2 Units ...... 23427. Added AA Gate Backplane Wiring Changes For Dual IM DL3 Units .............. 23428. Added AA Gate Backplane Wiring Changes For Dual IM DL3 Units .............. 23529. PROM and PCBA Minimum Levels ........................................................... 235

211. U4 Electronics Gate PCBA Locations ...................................................... 249212. POL Cable Connections ......................................................................... 250213. EMI 5-Volt Power Supply Connections ..................................................... 261214. Internal Backplane Cable and Harness Connections .................................. 268215. Harnesses Attached to the PS Cover ...................................................... 269216. AC Harnesses ....................................................................................... 269

41. U4 Imaging Module Cables and Harnesses .............................................. 4442. JPEG Imaging Module Cables and Harnesses ........................................... 4643. U4 Image Gate Cables and Harnesses .................................................... 44744. PCBA Jumper Settings ........................................................................... 45645. JPEG Cables and Harnesses to Disconnect ............................................. 45846. JPEG Image Gate Cables and Harnesses ................................................. 460

47. Cables and Harnesses to Disconnect from the PSU Cover Panel ............... 46548. Cables and Harnesses to Reconnect to the Internal PSU Cover Panel ........ 46649. JPEG PCBA Jumper Setting .................................................................... 470

A1. Imaging Module SEIs and T&As .............................................................. A1


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2983 7986203 Unisys Proprietary - Class B xv

About This Guide

This guide provides procedures for installing and servicing these modules:

Image Item Processing System (IIPS) IC 1000, IC 1000-J, IC 1800, IC 1825, IC 1825-J,

and IC 1800-JU Imaging Module (IM)

References to the Imaging Modules are labeled IC 1XXX throughout this guide.

References to the document processors DP 1000, DP 1800, and DP 1825 are labeled

DP 1XXX throughout this guide.

NDP 1000-4X/NDP 1825-4X Imaging Module (dual image)

References to the NDP document processors are labeled NDP 1XXX throughout this

guide.

Purpose

This guide provides an overview of the IM and dual IM components and their

maintenance. It also provides installation procedures. Drawings showing the locations of

the serviceable modules are included.

Scope

For the IM, this guide applies to the IC 1XXX Imaging Module. Other components of IIPS

are documented in separate guides.

For the dual IM, this guide applies to the NDP 1000-4X/NDP 1825-4X Imaging Module.

Other NDP components are documented in separate guides.

Audience

This guide is for Unisys Client Service Engineers (CSEs) who install and service the IM or

dual IM.

PrerequisitesPersonnel using this guide should have a basic understanding of IIPS and NDP. IIPS

information is available in the Image Item Processing System (IIPS) Servicing Guide:

Maintenance.


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About This Guide

xvi Unisys Proprietary - Class B 2983 7986203

Organization

This guide consists of the following sections and appendixes. In addition, a glossary and

an index appear at the end of this guide.

Section 1. Operation and Components

This section introduces the modules, describes their operation, and provides a description

of the major components.

Section 2. Imaging Module Installation on a Document Processor

This section provides procedures for installing the IM or dual IM into an existing or

factory-prepped document processor.

Section 3. IC 1000/IC 1825 Imaging Module Components

This section describes the documentation shipped with the IM or dual IM and thetechnical documents related to the module, and provides illustrations with locations of the

major components for the IM.

Section 4. Maintaining the IC 1000/IC 1825 Imaging Module

This section provides detailed procedures used in IM maintenance. Topics include

removal and replacement procedures for field replaceable modules (FRMs), tests and

adjustments, and preventive maintenance.

Section 5. Maintaining the NDP 1000-4X/NDP 1825-4X Imaging Module

This section provides detailed procedures used in dual IM maintenance. Topics include

removal and replacement procedures for field replaceable modules (FRMs).

Appendix A. Special Engineering Instructions and Tests and Adjustments

This appendix provides special engineering instructions (SEIs) and tests and adjustments.

Results

Having read this guide, you should understand how to install and service the IM and dual

IM.


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About This Guide

2983 7986203 Unisys Proprietary - Class B xvii

Related Product Information

The following documents complement this guide.

DP 1000/DP 1800/DP 1825 Servicing Guide: Parts Catalog (2983 9396)

This guide provides illustrations and field replacement unit (FRU) part numbers for all DP

1000/DP 1800/DP 1825 FRMs.

DP 1800 Servicing Guide: Maintenance Procedures for DL1 and DL2

(2983 8653)

This guide provides maintenance procedures for the DL1 and DL2 versions of the DP 1800

Document Processor.

DP 1825 Installation Guide (2983 8984)

This guide provides procedures for the installation and maintenance of the DP 1825Document Processor.

IC 1000/IC 1825 Imaging Module Operations Guide (2983 8679)

This guide provides operation procedures for the Imaging Module.

Image Item Processing System (IIPS) Servicing Guide: Diagnostic Procedures

(2983 4706)

This guide provides diagnostic procedures for IIPS.

Image Item Processing System (IIPS) Servicing Guide: Maintenance

(2983 8091)

This guide provides maintenance procedures and maintenance test routines (MTRs) for

IIPS.

IR 9210 Courtesy Amount Read (CAR) Module Capabilities Overview

(2946 1351)

This document provides an overview of CAR module operations. It also describes the

CAR module hardware, application software, and important preinstallation considerations.

IR 9210 Courtesy Amount Read (CAR) Module Servicing Guide: Parts Catalog

(2496 1468)

This manual illustrates the components of the CAR module and identifies part numbers.

IR 9210 Courtesy Amount Read (CAR) Module Site Preparation Data Sheet

(2983 9263)

This document presents the information necessary for the customer to prepare the site for

the CAR module. It describes the requirements for space, environmental control, and

power.


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About This Guide

xviii Unisys Proprietary - Class B 2983 7986203

IR 9210/IR 9220 Courtesy Amount Read (CAR) Servicing Guide: Diagnostic

Procedures (2983 7853)

This manual provides diagnostic procedures and maintenance test routines for the CAR

module.

IR 9210/IR 9220 Courtesy Amount Read (CAR) Servicing Guide: Installation

and Maintenance (2983 7804)

This guide provides an introduction to the CAR module, installation instructions, and

removal and replacement procedures.

NDP Capabilities Overview (3998 1956)

This document provides an overview of NDP operations. It describes the document

processors and modules, system software, enhancements, and important preinstallation

considerations.

NDP Operations Guide (3998 1923)

This guide provides operation procedures for the NDP document processor, including the

NDP PC, HSEM, and the NDP 1000-4X/NDP 1825-4X Imaging Module.

NDP Servicing Guide: Hardware Installation (3998 5585)

This guide provides procedures for the installation of the Network Document Processor

hardware.

NDP Servicing Guide: Maintenance Procedures (DL3) (3998 5593)

This guide provides the maintenance test routine (MTR) information for the NDP 1150 and

NDP 1825 Document Processors.

NDP Servicing Guide: Parts Catalog (3998 5601)

This guide provides illustrations and field replacement unit (FRU) part numbers for all

NDP FRMs.

NDP/DP 1000/DP 1825 Servicing Guide: Analysis and Test Software

(2983 9289)

This guide provides information on the diagnostic programs available for the CSE to

discover and resolve problems in the operation of the NDP and DP 1XXX document

processors.

NDP 1000-4X/NDP 1825-4X Imaging Module Image Capture Server Software

Installation and Operations Guide (4326 4878)

This guide provides procedures for installing the Image Capture Server software, running

the Trace Function and Storage Connectivity Test, and running the Common Application

Programming Interface Exerciser. The guide also describes the Communicates for the

image platform.


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About This Guide

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2983 7986203 Unisys Proprietary - Class B 11

Section 1 Operation and Components

This section introduces the IC 1000/IC 1825 and NDP 1000-4X/NDP 1825-4X imaging

modules and describes the operation and the major components of the modules.

IC 1000/IC 1825 Imaging Module

This subsection describes the operation, interfaces, and imaging module (IM)

components.

Operation

The IM is composed of hardware and software that capture, digitize, process, compress,

and package images as they pass through a document processor. Document images are

captured as they are sorted. In a high-speed document processor, for a DP 1825 the

sorting speed is 1,825 documents per minute (at a track speed of 300 inches per second).

The sorting speed is 1,000 documents a minute (a track speed of 150 inches per second)

for a DP 1000.

As each document passes along the document processor track, an intense vertical stripe

of light is directed to both sides of the document. The light contacts the document and is

reflected to a set of mirrors. It is then focused through a lens and onto the camera printed

circuit board assembly (PCBA).

The camera PCBA measures the light reflected from the document in analog voltage

values and then sends the data to the electronics gate submodule for processing,

compression, and temporary storage. Image packets (made up of document image data)

are then sent to the IR 9000 Series Storage and Retrieval Module for later retrieval by

image workstations (IWSs). The images are used in image-based applications and may be

printed.

Note: For additional system-level information, refer to the Image Item Processing

System (IIPS) Functional Overview.

Figure 1-1 shows the IM installed in a DP 1XXX Document Processor. The IC 1000-J

Imaging Module, located on the DP 1000 Document Processor, and the IC 1825-J Imaging

Module, located on the DP 1825 Document Processor, are positioned between the Area 1

module and the first pocket module. If your document processor also includes the

optional microfilmer, the imaging module is located between the microfilmer and the first

pocket module, as shown in Figure 1-1.


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Operation and Components

12 Unisys Proprietary - Class B 2983 7986203

Figure 11. DP 1XXX Document Processor With IC 1XXX Imaging Module

The IM performs the following functions within IIPS:

Accepts User Sort Program (USP) commands and data from the document processor

Captures document images

Digitizes document images

Performs image processing operations on document images

Compresses document image data

Stores image and document-specific data temporarily

Transmits image and document data (image packets) to the SRM

Accepts unit management commands from the host processor

Obtains configuration information from the host processor and SRM

Imaging Module Interfaces

The IM communicates with four IIPS modules:

Document processor

Host processor

SRM

Courtesy amount read (CAR) module (an option with IIPS)

The document processor forwards transport status requests to the IM. Imaging statistics,

image system status, diagnostic information, and responses to the USP requests are

passed from the IM to the document processor.

The IM sends image data and file manipulation requests to the SRM through a fiber optic

link. The SRM passes file manipulation responses and initialization data to the IM.


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The IM receives system configuration management requests from the host processor

through the SRM.

When the CAR module is installed, the CAR port board is located in the electronics gate

submodule. The IM sends image segments to the CAR port board. A video cable sends theimage segment from the CAR Port board to the Pixel Unit board inside the CAR module.

Figure 1-2 shows how the IM is connected to other IIPS components.

Figure 12. Imaging Module System Interfaces


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Imaging Module Components

The IM is made up of two major components, the camera submodule and the electronics

gate submodule. The camera submodule is located in a transport module of the sorter,

between the microfilmer (if one is present) and the first pocket module. The electronicsgate submodule is located in the lower portion of the first pocket module.

There are two different electronics gates available for image compression and

decompression in the IM, U4 and Joint Photographic Experts Group (JPEG). The U4

system, a Unisys proprietary compression/decompression system, has a 5-volt power

supply that is mounted outside the imaging module electronics gate. It distributes five

volts direct current (VDC) to the electronics gate through a fan panel and electromagnetic

interference (EMI) shield by way of several cables. The industry standard JPEG system

also uses a 5-volt power supply. This power supply, however, is mounted inside the

electronics gate and EMI shield that protrudes through the frame of the adjoining module.

The power supply distributes five VDC to the electronics gate by way of Teflon-coated

copper ribbon cables.

Note: JPEG is the only electronic gate available in the DP 1000 document processor.

The camera submodule, lamps, and electronics gate submodule each have their own

power supplies.


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NDP 1000-4X/NDP 1825-4X Imaging Module

This subsection describes the operation, interfaces, and dual IM components.

Operation

The dual IM is composed of hardware and software that captures, digitizes, processes,

compresses, and packages image as they pass though a document processor. Document

images are captured as documents are sorted. The NDP 1825 has a track speed of 300

inches per second (approximately 1825 images per second) and the NDP 1150 has a track

speed of 150 inches per second (approximately 1000 images per second).

The dual IM illuminates and captures a digital image of each document that passes down

the transport. The image is framed, compressed, and then retrieved by an Image Capture

Server (ICS) for subsequent delivery to an Image File Server (IFS). The document

processor also provides document-related information to the ICS through the dual IM.

Figure 1-1 shows the dual IM installed in a NDP 1XXX Document Processor.

1

2

3

4

5

6

7

Legend

1. PC module 5. Microfilmer

2. Basic unit 6 Imaging module

3. RMJE or FMJE 7. 8-pocket modules

4. High Speed Encoder (Basic module, add-on module,

(NDP 1150 only) (and controller module)

Figure 13. NDP 1XXX Document Processor With NDP 1000-4X/NDP 1825-4X ImagingModule (Dual IM)

The dual IM also has provisions for providing video to an optional Courtesy Amount Read

unit.


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Imaging Module Components

The dual IM is a transport module of the NDP 1XXX. It is the last transport module before

the pocket modules. If a microfilmer is present in the system, the dual IM provides the belt

drive to its transport.

The dual IM lamps and solid state cameras are mounted above the transport baseplate.

The lamps are located under a hinged enclosure at the front of the module. The transports

top cover has an interlock that dims the lamps when the cover is raised. The lamp

enclosure cover also has an interlock that extinguishes the lamps when the operator raises

the lamp cover to change the lamps or the CSE raises the lamp cover to service

components under the cover. The dual IM uses four standard projection lamps (two per

camera). The cameras image the document through glass windows in the transport. As

each document passes along the document processor track, an vertical stripe of light is

directed to both sides of the document. The solid state image camera views the

illuminated documents and scans the document as a series of vertical stripes.

The signals from the camera are sent to electronic components in the logic gate that islocated in the base of the module. The electronic components correct the image data for

variations in illumination and camera sensitivity. The images are framed, finding the top,

bottom, leading, and trailing edges. Under direction of the User Sort Program (USP),

images are then compressed as black/white renditions by Consultative Committee on

International Telephone and Telegraph (CCITT) Group 3 or Group 4 compression and/or as

grayscale renditions with JPEG baseline compression. The dual IM is capable of providing

up to two compressed renditions of the front image and one rendition of the rear image per

document. Two compressor types are available as options for the rear image, however,

only one may be selected at a time. Image data is retrieved by the ICS for subsequent

delivery to an IFS. The ICS controls the document-to-document operations and

information transfers of the dual IM.

The power supplies for the dual IM are located in the base of the transport module. Onesupply provides 5V power for the logic and power for the lamps. A linear supply provides

power for the camera and analog circuits.

When the Hardware CAR module is installed, the CAR Port board is added to the dual IM

electronics gate. The CAR Port board provides the processed image stream that the CAR

unit requires. The CAR module for the NDP 1150 is located in the pocket module of the

transport while the CAR module for the NDP 1825 is in a stand-alone cabinet. The ICS

controls the operations of the CAR module through a differential SCSI link.

If CAR-ICR is installed, JPEG snippet compressors are installed in the logic gate to provide

the high resolution JPEG image required by this reader. The image snippets size and

position are controlled by the application software. The snippets are stored on the ICS or

IFS for retrieval by the CAR-ICR read system.


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Image Module Interfaces

The dual IM is composed of the transport module and the ICS. These communicate with

the external environment through the following interfaces:

Document processor interface

Image File Server interface

Courtesy Amount Read interface (optional for HardCAR only)

The document processor provides document related information such as MICR codelines

to the ICS. In turn, image system status and diagnostic information is passed back to the

document processor. The ICS transfers file information to the Image File Server for long

term storage and distribution over a dedicated LAN connection. The HardCAR Port board

provides the processed image stream that the CAR unit requires. The ICS controls the

operation of the HardCAR module through a differential SCSI link.


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Section 2 Imaging Module Installation on aDocument Processor

This section provides a detailed explanation of procedures for installing the IC 1000/

IC 1825 Imaging Module (IM) or NDP 1000-4X/NDP 1825-4X dual Imaging Module (dual

IM) into an existing or factory-prepped DP 1XXX or NDP 1XXX Document Processor. An

existing Document Processor is one that has already been installed at a customer site in

which imaging will now be added. A factory-prepped Document Processor is one that is

shipped to the customer ready to have imaging installed. The DP 18XX Document

Processors must have identification plates bearing a serial number 250 or higher. Thissignifies that the unit is at least Design Level 1 (DL1). All DP 1000s can have imaging

installed. The IM or dual IM is to be located just before the reject pocket.

Because of the many configurations of machines, some procedures in this section may not

be required at each installation. The term basic unit is used to refer to the portion of the

machine before an IM or dual IM, whether it is a microfilmer, a non-impact endorser (NIE)

module, or a standard Area 1.

The intent of this installation procedure is to break apart the document processor, install

the IM or dual IM into the document processor, and run checks in the shortest time. The

module can then be completed and brought up to full working level when time permits.

This allows a customer to have quicker access to a machine which may be needed sooner

than otherwise possible if all of the installation and check out were to be completed at onetime.

The following tasks may be completed prior to the actual installation of the IM or dual IM

since they serve to make the document processor image ready:

Customer installation of a 75 ampere circuit breaker on the power line for the

DP 18XX document processor or a 60 ampere circuit breaker for the DP 1000 or

NDP 1XXX document processor. Refer to the IC 1825 Imaging Module Site

Preparation Data Sheet and seeDocument Processor Circuit Breaker Upgrade, the

next topic in this section. The document processor cannot capture images if this task

has not been completed.

Circuit breaker upgrade (if required).

Four-pocket to eight-pocket upgrade. Refer to special engineering instruction (SEI)

4139 5260.

Note: Refer to the IR 9210/IR 9220 Courtesy Amount Read (CAR) Module Servicing

Guide: Installation and Maintenance for instructions on installing the CAR

Port board and the video cables that connect the CAR Port board to the CAR

module.


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Imaging Module Installation on a Document Processor


Document Processor Circuit Breaker Upgrade

DP 1800 Document Processors with serial numbers 330274069 and lower and DP 1000

Document Processors with serial numbers 372521930 and lower must have the entire

circuit breaker box replaced. A distinguishing feature of the units requiring this change isto check the Area 1 circuit breaker panel. If the label for the breaker in the upper left

corner of the panel is C/M Main, the unit needs to be replaced for image. This upgrade

can be done in advance of the IM installation without affecting the normal operation of the

document processor except for the downtime required to do the work. If the upgrade is

not required, go to Unpacking the Imaging Module later in this section. Otherwise, refer

to the following instructions and Figure 2-1. Use kit UC 201801 (3305 7571).

WARNING

Shut off electrical power to the document processor before proceeding

with installation. Injury may result from electrical shock. The documentprocessor is hard-wired to the facility power supply. Power must be shutoff from the facility circuit breaker panel. Check to be sure power hasbeen shut off before proceeding.

1. Remove the Area 1 rear panel and the left end panel and set them aside.

2. Open the front panel of the circuit breaker box in the Area 1 module at the rear of the

machine.

3. Measure the voltage across the two top lugs on the basic unit circuit breaker (CBBU)

and the control module circuit breaker (CBCM), if present. If the voltage is not zero,

do not proceed until power is removed from the line.

4. Remove the sheet metal cover from the bottom of the radio frequency interference

(RFI) filter located on the back panel of the breaker housing.

5. Remove the three power leads from the terminals on the bottom end of the filter. Set

the hardware aside for later reassembly.

6. Loosen the black flexible conduit from the metal bulkhead, and pull the three wires

and conduit out of the box.

7. Remove the plastic cover mounted at the top of the RFI filter. Remove the two line

leads from the output terminals of the filter.

8. If present, disconnect the control module power cable from its circuit breaker, and

remove the cable completely from the housing. See Figure 2-1.


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Figure 21. Circuit Breaker Housing

9. Remove the two screws from the rear of the document processor that serve as pivots,

thereby disconnecting the circuit breaker panel from the housing. Lay the panel on

the floor or on a box behind the document processor as far as the harness length will

allow.

10. Remove the screws securing the circuit breaker housing to the frame. Remove the

green/yellow wire frame ground from the housing. Set aside the hardware for later

reassembly.

11. Remove the black plastic conduit fitting from the old housing.

12. Remove all connections of the input cables going to the circuit breakers, and label

these wires to ensure proper reinstallation.

13. Remove the strain relief bushings from the old panel.

14. Locate the new housing supplied with the upgrade kit, and orient it beside the

housing. Attach the black plastic conduit connector and the strain relief cable clamps

to the bottom of the new housing.

15. Remove the RFI filter from the back surface of the old housing. Relocate the filter

inside the new housing with the two LOAD terminals facing the open end of the

housing, and secure with three washers and nuts.


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16. Locate and secure the black terminal strip to the left inside wall of the housing.

17. Locate the two 11-inch long, 6-AWG white jumpers and the one 6-AWG, green/yellow

ground jumper supplied with the kit. Connect the two white wires to the two input

terminals on the top end of the filter marked LINE, using the hardware previously

removed.

18. Secure the ground wire to the ground terminal of the filter.

19. Connect the other ends of the two input jumpers to the top positions of the terminal

strip.

20. Position the new housing inside the document processor frame and secure with

hardware previously removed.

Note: It may be necessary to bend the item counter terminals away from the

housing and wrap them with several turns of electrical tape to avoid an

electrical short between the terminals and the item counter.

21. Feed the three leads of the power input cable through the plastic fitting on thehousing. If the plastic conduit is too long, cut off the excess. Connect the conduit to

the fitting.

22. Connect the two line leads of the input cable to the bottom of the terminal strip on the

side wall, using the lugs from the previous hook-up. Connect the lugs using a flat

washer on each side, and a lock washer.

23. Connect the ground conductor to the ground point on the right wall of the housing,

CBGRD-2A, along with the other end of the ground jumper attached to the filter. The

ground conductor in the power cord must have more slack than the two HOT leads, so

that if the power cable is pulled, the ground wire is the last one to break.

24. Reattach the green/yellow wire frame ground (previously removed from the old

housing) to the new housing.

25. Use the following procedure to transfer the entire bank of circuit breakers from the

old panel to the new panel:

a. Loosen the entire set of breakers, fuse(s), and the terminal strip. Transfer all to

the new panel.

b. Do one of the following:

If a control module is not present, skip to Step 25c of this procedure.

If a control module is present, locate the new control module breaker

provided with the kit. Mount it at the appropriate opening in the bottom row.

c. Transfer any plugs used on the old panel to fill unused openings on the new panel.

Verify that all wires are firmly and completely mounted to the breaker terminals.26. Refer to wiring instructions 2494 0835 and 3135 7270 for the proper wiring of the new

control module breaker.

27. Position the new panel in the new housing and secure in place with the two screws

previously removed.


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28. Replace the Area 2 AC harness and the control module AC power harness (if present)

with the new versions supplied with the upgrade kit.

The longer Area 2 harness allows for the extra length to go through the IM. The

control module harness has new terminals for the new circuit breaker. Refer to

schematic sheet 03.05.XX for the harness connections.

Note: If complete image installation is being performed, do not route the control

module AC power harness until after the IM is installed.

29. Route the harnesses removed in step 11 through the strain relief bushings and attach

to the proper terminals according to labeling done at the time of removal.

30. Install the two main input jumpers feeding the main circuit breaker to the load

terminals of the RFI filter, using the hardware previously removed.

31. Do one of the following:

Complete the image installation: Continue with Unpacking the Imaging Module,

next in this section. Do not complete the image installation at this time:

a. Perform the DP 1800 pre-power on check out procedure. Refer to Section 2,

Installation, in theDP 1000/DP 1825 Operations Guide.

b. Close the circuit breaker panel and reset all breakers.

c. Perform the DP 1800 power on check out procedure. Refer to Section 2,

Installation, in theDP 1000/DP 1825 Operations Guide.

d. Install the left-end panel and the rear panel.

e. Verify correct operation.


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Unpacking the Imaging Module

Use the following procedure to unpack the IC 1000/IC 1825 IM or NDP 1000-4X/

NDP 1825-4X (dual) IM:

WARNING

Use two or more trained Unisys personnel to move the module off of thepallet. Failure to do so may result in injury.

1. Cut the two straps around the outside of the box.

2. Lift the box off of the unit.

3. Remove the clear plastic cover.

4. Unbolt and remove the piece of wood from the front of the pallet and unbolt the

holding clamp on the side of the pallet.

5. Remove the front and rear panels from the IM or dual IM.

6. Slide the module off the pallet onto the floor.

7. Inspect the module for damage before installing. Record comments in a log book.

8. Open the module top cover, and remove all packing materials.


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Preparing the Document Processor

Use the following steps to prepare the document processor for installing the IM or dual

IM:

WARNING

Shut off electrical power to the document processor before proceedingwith installation. Injury may result from electrical shock. The documentprocessor is hard-wired to the facility power supply. Power must be shutoff from the facility circuit breaker panel. Check to be sure power hasbeen shut off before proceeding.

1. Remove the left-end, front, and rear panels from the document processor, and set

them aside for later installation.

2. Remove the quarter panel and lower mounting bracket (if present) from the right end

of the basic unit. Set them aside for later installation on the IM or dual IM.


If the document processor is not already installed, skip to Installing the Imaging

Module later in this section.

If the document processor is installed, continue with step 4 for DP 1XXX units or

step 5 for NDP 1XXX units to disconnect all mechanical and electrical

connections between the pocket modules and the rest of the document processor.

Refer to Figure 2-1.

Note: Mark any cables that do not have labels to insure that the proper cableconnections are made.

4. For DL1/DL2 DP 1XXX field upgrades, do the following:

a. Disconnect the DC inter-connect harness (three white wires) from the first, fifth,

and ninth pocket module driver boards (if present) and pull the cable(s) back past

the reject pocket into the basic unit. Access is from the rear of the machine.



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Figure 22. Document Processor Electrical Connections

b. Disconnect the signal harness (multicolored ribbon cable) from the first, fifth, and

ninth pocket module driver boards (if present), and pull the cable(s) back past the

reject pocket into the basic unit.

c. Disconnect the control module AC cable from the circuit breaker CBCM in Area 1,

if present. Pull the cable into the first pocket module.

d. Disconnect the AC and DC NIE harnesses, if present, (that run to the pocket

module) from the NIE power supply terminal strip. See Table 2-1.

Table 21. NIE Power Supply Connection

Harness Wire No. ESTB No.

AC 1 and 8 ESTB1-A

2 and 9 ESTB1-B

DC 1 and 2 ESTB2-A

3 and 35 ESTB2-A

5 ESTB2-C

4. 35. 36 ESTB2-D

6 ESTB2-E

e. Disconnect the AC control cables listed in Table 2-2 from the basic pocket module

and pull them back past the reject pocket into the basic unit or into the pocket

module, if applicable.


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Table 22. AC Control Cables

Cable Designation Plug Location

PICP1 from PICJ1 or MICJ1 Frame bottom

PICP2 from PICJ2 or MICJ2 Frame bottom

CABP1 from CABJ1 AC control gate

CAB8 from CABJ8 AC control gate

CABP9 from CABJ9 AC control gate

f. Go to step 6 of this procedure.

5. For DL3 (NDP 1XXX) field upgrades, disconnect the following cables, depending on

the option configuration.

a. Disconnect the following cables from Area 1 and pull them down into the first

pocket section:

Disconnect the Area 3 DC cable from the DC distribution PCBA, if present.

Disconnect the Area 4 DC cable from the DC distribution PCBA, if present.

Disconnect the control module AC cable from the circuit breaker CBCM in

Area 1, if present.

Disconnect the Area 2 AC harness from the back of the AC distribution cable.

b. Disconnect the following cables from the first pocket module 4-pocket driver card

and pull them back toward Area 1:

Area 2 DC harness

Area 2/3/4 interface harness

6. Disconnect the braided ground jumper bolted between the stacker frame and the

basic unit frame at the basic unit end.

7. Remove the full pocket switch and bracket for the reject pocket and place in the

pocket as the wires permit.

8. Remove the black plastic roller support, the stacker floor, and the metal front wall

(near the fascia plate) associated with the reject pocket. Set aside for later

reassembly.

9. If a microfilmer is present, loosen the idler pulley on the timing belt (underneath the

Area 2 baseplate) that transfers drive to the microfilmer module. Remove the belt.

10. Slice the foam strip along the bottom front and rear of the unit (along the floor)

between the first pocket module and the basic unit.

11. Remove the nuts, lock washers, and shoulder bolts connecting the first pocket module

to the basic unit.

Note: On units with TDC microfilm, retain all washers and rubber bushings for

later reassembly using the shorter shoulder bolts supplied with the IM.


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Installing the Imaging Module

Use the following procedure to install the Imaging Module.

1. Position the pocket modules so there is approximately 57.8 centimeters (22.75 inches)between the basic unit and the pocket modules.

2. Locate the EMI ground strip (a pliable 32-inch long strip of rubber covered with a fine

wire mesh) supplied with the IM. Using a strip of masking tape at each end, attach the

EMI ground strip to the bottom of the image frame, along the left side (as viewed from

the front of the module). Be sure that the strip touches the area of dull, black,

conductive paint. This strip must press against the basic unit frame when the modules

are joined together.

3. Slide the IM carefully into place adjacent to the basic unit.

4. Adjust the IM leveling feet so that the image base plate bolt holes in the side flanges

are vertically aligned with the corresponding holes in the basic unit.

5. Locate the proper shoulder bolts (supplied with the IM) for connecting the IM to the

basic unit. Refer to Figure 2-3 and Table 2-3.


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Figure 23. Image Module Shoulder Bolt Connections

6. Attach the IM loosely to the basic unit. Install the rear shoulder bolt first.

7. Verify that the 24-inch long EMI ground strip is attached to the lower left end of thestacker frame. Slide the stacker module(s) into position next to the IM and attach the

IM unit to the stacker module. Install the rear shoulder bolt first.

8. Level the entire unit.

Note: The entire unit must be leveled at this time, even if this is an upgrade to a

previously installed unit. See Leveling the Machine, the next topic in this

section.


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Table 23. IM Shoulder Bolt Usage

To Connect To: Use Bolt P/N Shoulder Length

Area 1 2111 2925 1.75

NIE 2111 2933 1.50

TDC Microfilm 2111 2933 1.50

Unisys Microfilm 1105 6520 1.00

Area 2 2111 2933 1.50

Notes:

All bolts use 1256 7491 lock washer and 1256 5420 nut supplied.

On units with TDC microfilm, use all washers and rubber bushings previously

removed with the bolts referred to in Table 2-3.


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Leveling the Machine

After all the required modules have been positioned and loosely secured, perform the

following procedure to level the modules.

1. Install two alignment posts on the right-hand side of the right-hand baseplate

assembly.

2. Install two alignment posts on the left-hand side of the left-hand baseplate assembly.

3. Remove the panel brackets at the left end of the Area 1 module, if present.

4. Remove the ground strap at the front right end of the Area 1 module.

5. Install four alignment posts on the Area 1 Module.

6. Attach a string to the alignment posts between the left end of the Area 1 module and

the right-hand baseplate assembly. Refer to Figure 2-4.

Figure 24. Bolting and Alignment of 8-Pocket Modules

7. To verify that there is enough adjustment of the feet to compensate for floor

irregularities, adjust the left and right feet of the basic stacker module until the string

touches the right Area 1 post and the left stacker posts. This is an approximation of

machine level.


43/274



8. If very little adjustment is left on the stacker feet, you will need to reposition the Area

1 plane slightly by raising or lowering its feet and repeating Step 7. Otherwise, for

long machine, the last pocket module might not be adjustable.

9. Having estimated machine adjustability, install two leveling posts on each endorser,

high speed encoder, microfilmer, and Imaging Module, if present. If the optional TDC

microfilmer is present on an upgrade, there might be places for four posts. Install all

four posts.

Note: It is important that the string pass over the center of each post along the

length of the machine. If this is not the case, movement of a module might

be required. Slight repositioning of an end module or even an intermediate

module creates large results in the centering of the posts and string.

10. Using the four posts on the Area 1 baseplate as planes of reference, perform the

following to each downstream module.

a. Tighten the baseplate coupling bolts.

b. Adjust the left module feet so they are off the ground.

c. Adjust the right module feet so that the string, when pinched on that module's

right most post, contacts all posts back to the left end of Area 1. See Figure 2-4.

d. Adjust the left module feet to touch the floor and carry some of the module

weight; verify that the level has not been disturbed.

e. Tighten the locknuts on each foot.

Note: If the optional TDC microfilmer is part of an upgrade, be sure the

coupling hardware, including the blue rubber pads, are correctly

installed. Do not overtighten and squash the blue rubber pads.

11. If more pocket modules need to be installed, leave all leveling posts installed and go to

Section 2 of theNDP Servicing Guide: Hardware Installation, "Attaching 8-Pocket

Modules, Step 2.

12. Tighten all the module coupling bolts/nuts.

13. Reinstall the ground strap removed in step 5 after the leveling operation is complete.

14. Tighten all of the locknuts on all of the leveling feet.


If a microfilmer module is not present, skip to Drive Installation - No Microfilm

found later in this section.

If a microfilmer module is present, continue with Installing Microfilmer Drive

Transfer Components, next.


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Installing Microfilmer Drive Transfer Components

To pass the drive through the IM to the microfilmer module, transfer pulleys must be

assembled to the IM base plate. The necessary pulleys and belts are found in the

microfilmer drive transfer kit. Refer to Figure 2-5 to install the kit.

Im a ge D rive Tow e r

S p a c e r

E xisting N uta nd W ashe r

B elt

E xisting N uta nd W ashe r

Idler A ssem bly

B elt

M icrofilm

D rive P u lley

P ulley A ssem bly w ith K ey

E xisting P ulley a nd S pa cer

4

6

7

5

Figure 25. Timing Belt Installation

Do one of the following:

For Unisys microfilmers, skip to Drive Installation - Unisys Microfilmer, later in

this section.

For TDC microfilmers, continue with Drive Installation - TDC Microfilmer, next.

If there is no microfilm, go to Drive Installation - No Microfilmer, later in this

section.


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Drive Installation - TDC Microfilmer

Use the following procedure to install the drive belt from the IM to the TDC microfilmer

module:

1. Loosen the bottom lock nut, using a wrench on the flats at the bottom of the stacker

drive shaft to prevent the shaft from rotating.

2. Remove the nut, washer, and the timing pulley on the bottom of the shaft. Discard the

timing pulley.

3. Locate and install the 16-tooth timing pulley supplied with the IM on the bottom of the

shaft.

4. Install the washer and lock nut. Tighten the nut using a wrench on the flats of the

shaft to prevent the shaft from rotating.

5. Install the timing belt supplied with the image drive kit over the pulley on the bottom

of the stacker drive shaft and the pulley on the bottom of the IM drive shaft. Tension

the belt according to T&A 3304 2078 found in Appendix A of this guide, Special

Engineering Instructions and Tests and Adjustments.

6. Go to Microfilmer Air Hose Relocation, found later in this section for the IC 1000/

IC 1825 Imaging Module.

Drive Installation - Unisys Microfilmer

Use the following procedure to install the drive belt from the IM to the TDC microfilmer

module:

1. Install the timing belt (which was previously used to drive the microfilmer module)

over the pulley on the bottom of the stacker drive shaft and the pulley on the bottomof the IM drive shaft. Tension the belt according to T&A 3304 2078 found in Appendix

A, Special Engineering Instructions and Tests and Adjustments.

2. Continue with Microfilmer Air Hose Relocation, next, for the IC 1000/IC 1825

Imaging Module.

Microfilmer Air Hose Relocation

Use the following procedure to relocate the microfilmer air hose(s) section for the

IC 1000/IC 1825 Imaging Module:

1. Locate the black hoses supplied in the microfilmer drive kit. To install these in the

microfilmer module, refer to SEI 3304 5097 found in Appendix A, Special EngineeringInstructions and Tests and Adjustments.

2. For the IC 1000/IC 1825 Imaging Module, go to Reject Pocket Assembly, found later

in this section. For the NDP 1000-4X/NDP 1825-4X Imaging Module, go to Cooling

Change Installation For the NDP 1000-4X/NDP 1825-4X Imaging Module later in this

section.


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Drive Installation - No Microfilmer

Choose one of the following to install the drive pulley where no microfilmer is present:

If there is no idler arm on the bottom of the stacker bearing housing, continue withProcedure A, next.

If there is already an idler arm on the bottom of the stacker bearing housing, skip to

Procedure B, found later in this subsection.

Procedure A

Use the following procedure to install a drive pulley where there is not an existing idler

arm idler arm. Refer to Figure 2-6.

1. Loosen the tension on the add-on pocket module (pockets 3 through 6) drive belt by

swinging the idler away from the belt. Remove the belt.

2. Loosen the tension on the drive input timing belt by moving the motor toward the

bearing housing. Remove the belt.

3. Remove the stretch poly-vee belt that drives the pocket augers.



5. Remove the nut, the washer, and the spacer on the bottom of the shaft. Discard the

spacer.

6. Remove the three pulleys and one spacer and key. Keep all parts in the same

sequence for later reassembly.

7. Place the idler pulley and arm assembly supplied with the image drive kit on the

bearing housing base and secure in place.

8. Reassemble pulleys previously removed from the shaft, substituting the longer key

provided in the image drive kit.


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Figure 26. Idler Arm and Pulley Installation

9. Locate and install the 16-tooth timing pulley supplied with the IM drive kit.



11. Install the poly-vee auger belt, using an adjacent module as a guide to get the proper

twist on the belt. This determines the direction of rotation on the augers.

12. Install and tension the drive input belt from the motor according to the T&A found in

the document processor T&A package. This requires positioning the motor.

13. Install and tension the add-on pocket module drive belt according to the T&A found in

the document processor T&A package.



the belt according to T&A 3304 2078 found in Appendix A, Special Engineering

Instructions and Tests and Adjustments.

15. For the IC 1000/IC 1825 Imaging Module, go to Reject Pocket Assembly, found later

in this section. For the NDP 1000-4X/NDP 1825-4X Imaging Module, go to Cooling

Change Installation For the NDP 1000-4X/NDP 1824-4X Imaging Module later in this

section.


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Procedure B

Use the following procedure to install a drive pulley where there is an existing idler arm.


1. Locate the idler pulley and arm assembly supplied in the image drive kit. Remove the

pulley and post from the arm. Mount the post and pulley to the arm on the bottom of

the stacker bearing housing. Discard the extra arm.



3. Remove the nut, washer, and the spacer on the bottom of the shaft. Discard the

spacer.

4. Locate the key supplied in the image drive kit. Remove the key from the remaining

pulleys on the shaft and replace it with the longer key.

5. Locate and install the 16-tooth timing pulley supplied with the IM.





the belt according to T&A 3304 2078 found in Appendix A, Special Engineering

Instructions and Tests and Adjustments.

8. Go to Reject Pocket Assembly later in this section for the IC 1000/IC 1825 Imaging

Module. For the NDP 1000-4X/NDP 1825-4X Imaging Module, continue to the next

procedure in this section, Cooling Change Installation For the NDP 1000-4X/

NDP 1825-4X Imaging Module.


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Cooling Change Installation For the NDP 1000-4X/NDP 1825-4X Imaging Module

For field upgrades, install the Unisys microfilmer, Area 1, and pocket module coolingchanges if they are not already present. Parts required for these changes are included in

the upgrade kit.

If the Unisys microfilmer is present, the blower motor must have an adapter to divert

some of its cooling air to blow onto the motor itself. Rearrange the hoses and attach the

air flow diversion adapter and restrictor as directed in the following steps:

1. Remove the air outlet hose completely from its current location along the floor of the

module.

2. Starting from the rear of the camera unit, rest the hose along the top of the steel

bracket. Wrap the hose under the steel bracket between the middle two frame side

supports. Thread a plastic tie wrap through the front-most drill hole in the steelbracket, and secure the hose with the tie wrap. Refer to Figures 2-7 and 2-8 for two

different views of the hose.

Figure 27. Relocating the Air Outlet Hose (Inside Module Looking Out)


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Figure 28. Relocating the Air Outlet Hose (Outside Module Looking In)

3. Referring to Figure 2-9, attach the air flow diversion adapter onto the air flow outlet

(where the outlet hose was previously attached). Position the adapter so that the two

holes face the blower motor (refer to dashed circles in Figure 2-9). Mount the

restrictor between the airflow diversion adapter and the output hose adapter, and

secure the outlet hose onto the adapter. Tighten both clamps to hold the adapter and

hose in place.


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Legend

1 Blower motor

2 Output hose

3 Output hose adapter

4 Restrictor

5 Air flowdiversion adapter

Figure 29. Detail of Air Flow Diversion Adapter Location

4. Relocate the input hose to the front right side of the Imaging Module on the bottom.

Cut the hose to length and secure it in place on the output bracket with the clamp that

is provided.

5. For the first 8-pocket module, make the cooling modification according to the

following steps:

a. Install the fan panel assembly with three fans to the middle frame members

below pocket 2. Use the screws and washers provided.

b. Mount the bracket with the single fan to the back frame member below the

reject pocket so that it blows air directly at the transport motor. Use the

screws and washers provided.

c. Connect the 3-fan harness together.


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d. On NDP units, connect all four fans and plug the 4-pin plug into connector

A2FAN on the motor capacitor plate. For DP units, connect it to CABP5 on

the AC control cage.

6. For the Area 1 AA gate, on NDP units only, add a baffle to direct air onto the top

power supply just like the lower power supply as follows:

a. Using the baffle as a template, mark the location of two holes 5.57 inches

from the bottom of the gate.

b. Tape a protective cover or cloth over the power supplies to prevent metal

shaving

image install servce

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