Pitney Bowes AddressRight DA50S User manual

Service Manual
DA50S/DA55S and DA70S/DA75S
AddressRight™ Shuttlehead Printers
DA50S (WS51) - Black
DA55S (WS56) - Black & Color
DA70S (WS71) - Black
DA75S (WS76) - Black & Color

FCC Compliance
This equipment had been tested and found to comply with the limits for a Class A digital device,
pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection
against interference when the equipment is operated in a commercial environment. This equipment
generates, uses, and can radiate radio frequency energy, and if not installed and used in accordance
with the users manuals, may cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference in which case the user will be
required to correct the interference at his own expense.
Shielded cables must be used with this unit to insure compliance with Class A limits.
Canadian DOC Compliance
This digital apparatus does not exceed in the Class A limits for radio noise emissions from digital ap-
paratus set out in the Interference-causing Equipment Regulations (Standard ICES-003) of the Ca-
nadian Department of Communications.
Le present appareil numerique n’emet pas de bruits radioelectriques depassant les limites appli-
cables aux appareils numeriques de la class A prescrites dans le Reglement sur le brouillage radio-
electrique edicte par le ministere des Communications du Canada.
NOTE: This equipment has been tested and found to comply with the U.S. Standard for Safety
UL1950, Third Edition, Safety of Information Technology Equipment including Electrical Business
Equipment and Canadian Standards C22.2 No 950-95, Third Edition, Safety of Information Technol-
ogy Equipment including Electrical Business Equipment
First Edition, March 2007
SV61831 Rev. A
©2007 Pitney Bowes Inc.
All rights reserved. This book may not be reproduced in whole or in part in any fashion or stored in a
retrieval system of any type or transmitted by any means, electronically or mechanically, without the
express written permission of Pitney Bowes Inc.
We have made every reasonable effort to assure the accuracy and usefulness of this manual, how-
ever, we cannot assume responsibility for errors or omissions or liability for the misuse or misappli-
cation of our products.

Table of Contents
DA50S/DA55S/DA70S/DA75S AddressRight™ Printers Service Manual iii
Chapter 1 – Introduction
1.1 Purpose of this Manual.............................................................. 1-1
1.2 Related Publications.................................................................. 1-1
1.3 Book Organization..................................................................... 1-2
1.4 Safety ........................................................................................ 1-2
Chapter 2 – Specifications
2.1 Product Description ................................................................... 2-1
2.2 System Requirements ............................................................... 2-1
2.3 Physical Equipment Specifications............................................ 2-2
2.4 Print Specifications.................................................................... 2-3
2.5 Material Specifications............................................................... 2-7
Chapter 3 - Theory
3.1 Changes From Earlier Models .................................................. 3-1
3.2 Printer Architecture.................................................................... 3-2
3.3 Operating Sequence.................................................................. 3-5
Chapter 4 - Troubleshooting/Diagnostics
4.1 Block Diagrams ......................................................................... 4-1
4.2 Main Controller Board Diagnostics............................................ 4-3
4.3 Troubleshooting Tables.............................................................. 4-7
4.4 Printer Error Codes.................................................................. 4-14
4.5 Print Samples for Troubleshooting .......................................... 4-15
Chapter 5 - Removal & Replacement
5.1 List of Procedures...................................................................... 5-1
DA50S/DA55S (WS51/WS56) Parts Removal
5.2 Covers ...................................................................................... 5-2
5.3 Display/Keyboard ..................................................................... 5-3
5.4 Main Processor Board/Grounding Sheet Assembly ................. 5-3
5.5 USB/Ethernet Input Board ........................................................ 5-4
5.6 Power Supply ........................................................................... 5-5
5.7 Paper Transport Motor/Belt ...................................................... 5-7
5.8 Sensor ...................................................................................... 5-9
5.9 Feed Roller Assembly ..............................................................5-11
5.10 Encoder and Operator Side Drive Belt ................................. 5-13

Table of Contents
iv SV61831 Rev. A DA50S/DA55S/DA70S/DA75S AddressRight™ Printers Service Manual
Chapter 5 - Removal & Replacement (continued)
DA70S/DA75S (WS71/WS76) Parts Removal
5.11 Covers .................................................................................. 5-15
5.12 Display/Keyboard ................................................................. 5-17
5.13 Main Processor Board/Grounding Sheet Assem. ................. 5-17
5.14 USB/Ethernet Input Board .................................................... 5-18
5.15 Power Supply ....................................................................... 5-18
5.16 Feed Roller Assembly............................................................ 5-19
5.17 Motor Drive Belts and Main Motor ........................................ 5-21
5.18 Exit Roller ............................................................................. 5-23
5.19 Sensor .................................................................................. 5-23
5.20 Shuttle Head Motor, Print Head, Shuttle Drive ..................... 5-24
5.21 H-Block Tip ........................................................................... 5-25
Chapter 6 - Adjustments
6.1 List of Adjustments .................................................................... 6-1
Adjustments for All Models
6.2 LCD Display .............................................................................. 6-2
6.3 Paper Sensor Test and Calibration ........................................... 6-2
DA50S/DA55S (WS51/WS56) Adjustments
6.4 Main Brake ............................................................................... 6-3
6.5 Printhead Clearance.................................................................. 6-5
6.6 Adjusting Exit Roller Idler Assembly .......................................... 6-6
6.7 Printhead Drive Belt .................................................................. 6-7
6.8 Main Drive Belt .......................................................................... 6-8
6.9 Adjusting Service Station Assembly .......................................... 6-9
DA70S/DA75S (WS71/WS76) Adjustments
6.10 Main Brake ............................................................................ 6-10
6.11 Print Head Drive Belt ............................................................. 6-10
6.12 Timing Belt .............................................................................6-11
6.13 Main Drive Belt .......................................................................6-11
6.14 Print Head Home Position ..................................................... 6-12

Table of Contents
DA50S/DA55S/DA70S/DA75S AddressRight™ Printers Service Manual v
Chapter 7 - Maintenance Procedures
7.1 General...................................................................................... 7-1
7.2 Specific Maintenance ................................................................ 7-2
Appendix A – Printer Control Panel Menus and Utilities
A.1 Control Panel Menus for the Printer..........................................A-1
A.2 LCD Control Panel Menu .........................................................A-3
A.2 LCD Main Menu .......................................................................A-4
A.3 LCD Setup Menu.......................................................................A-9
A.4 LCD Service Menu..................................................................A-19
A.5 Setting Factory Defaults (from LCD Menu).............................A-24
A.6 Updating Firmware..................................................................A-26
Appendix B – Printer Communications
B.1 Communication Scenarios ........................................................B-1
B.2 Troubleshooting Tables .............................................................B-4
B.3 Testing Printer Communications Within a Network ...................B-7
Appendix C – Schematics
Main Processor Board Schematic ....................................................C-2
LCD/Keypad .....................................................................................C-3
USB/Ethernet LAN Function.............................................................C-4
Black & White Printer Head..............................................................C-5
Color Print Head...............................................................................C-6
Index (not ready at time of publishing)........................ I-1

Table of Contents
vi SV61831 Rev. A DA50S/DA55S/DA70S/DA75S AddressRight™ Printers Service Manual

1 • Introduction
DA50S/DA55S/DA70S/DA75S AddressRight™ Printers Service Manual 1-1
This book contains instructions for troubleshooting and site repair of DA50S/
DA55S and DA70S/DA75S AddressRight™ shuttlehead printers. It also includes
complete product specifications and a section on theory for training purposes.
For reference, the table below shows the predecessor shuttle head models.
1.1 Purpose of
this Manual
DA50S/DA55S Operator Guide SV61663
DA50S/DA55S Quick Setup Instructions (customer) SV61933
DA50S/DA55S Install SV61664
DA50S/DA55S Parts List SV61832
DA70S/DA75S Operator Guide SV61665
DA70S/DA75S Quick Setup Instructions (customer) SV61934
DA70S/DA75S Install SV61666
DA70S/DA75S Parts List SV61919
For other information on the printers, refer to these sources:
• Software Control Panel Application (on the host PC) - see the help sys-
tem on the software.
• FAQs document - see the Customer Service website under the product
page for AddressRight™ printers.
• Training - see Enhanced AddressRight™ Shuttle Head Printers Self-Direct-
ed Course (GMS-MC-03246) at My Portfolio on the Pitney Bowes intranet.
• Training Job Aids - print the job aids for the software control panel appli-
cation (GMS-MC-03246JA) at My Portfolio on the Pitney Bowes intranet.
1.2 Related
Publications/
Information
New
Marketing
Model
New
PCN Printing Capability Speed Predecessor Marketing
Model
Predecessor
PCN
DA50S WS51 Black Up to 10,000
#10 or DL
envelopes
per hour
DA500 W660
DA55S WS56 Black & Pro-
cess Color
(CYMK)
Up to 10,000
#10 or DL
envelopes
per hour
DA550 W680
DA70S WS71 Black Up to 14,000
#10 or DL
envelopes
per hour
DA700 W707
DA75S WS76 Black & Pro-
cess Color
(CYMK)
Up to 14,000
#10 or DL
envelopes
per hour
DA750 W790

1-2 SV61831 Rev. A DA50S/DA55S/DA70S/DA75S AddressRight™ Printers Service Manual
1 • Introduction
Personal Safety
Follow these precautions for your own safety:
• Treat every circuit like a gun that may be loaded. It may not be “live,” but
be sure. Check with a neon tester or voltmeter, or simply unplug the ma-
chine.
• Know how to turn off the power in the work area and get help in an emer-
gency.
• Don’t work on equipment under power unless it’s absolutely necessary.
If you must, use extreme caution. Don’t grasp two sides of a live circuit
at the same time—use one hand when reaching into a circuit, touching
a grounded case or chassis with that wrist or elbow if possible. This pre-
vents current from passing through vital organs. Observe this rule when
connecting or disconnecting plugs or leads, or making any adjustments
on a live circuit.
Familiarize yourself with proper procedures and methods before you install,
operate or repair the equipment to avoid personal injury or damage to the
equipment. If you train service people or equipment operators, it is important to
explain safety precautions to your students and encourage safety awareness.
1.4 Safety Warning messages appear throughout this manual to alert you to potentially
hazardous conditions. Two designations indicate their relative seriousness:
WARNING! Calls attention to improper practices that
could result in a potentially serious, even lethal injury to
you or the customer.
CAUTION! Calls attention to practices that could
cause minor injury to you or a customer or that could
damage equipment or material.
Chapter 1: Introductory and safety information
Chapter 2: Product specifications
Chapter 3: Theory of operation
Chapter 4: Troubleshooting and Diagnostics
Chapter 5: Removal and replacement procedures
Chapter 5: Adjustment procedures
Chapter 7: Maintenance procedures
Appendix A: Printer Control Panel Menus
Appendix B: Printer Communications
Appendix C: Schematics/Diagrams
1.3 Book
Organization

DA50S/DA55S/DA70S/DA75S AddressRight™ Printers Service Manual 1-3
Introduction • 1
Personal Safety (continued)
• Don’t underestimate the danger of shock: 1 mA (1/1000 amp) is uncom-
fortable; 5 mA is dangerous —you may jump back and be injured; 12 mA
causes hand muscles to contract, so you cannot free yourself; 24 mA has
proven fatal; and 100 mA (1/10 amp) is likely to be fatal.
• Use the right tools for the job. A tool which slips can cause a short—or a
shock. Don’t reach into a circuit with metal tools, or while wearing rings or
a watch. Even in low voltage circuits, a metal object can short circuit two
terminals. When working on live circuits, use tools with insulated handles
and try to keep your tool hand grounded.
• Don’t bypass safety devices, particularly fuses. Three-wire outlets (120
Vac) are designed to ground equipment to make it safe. If a hot wire
shorts to a grounded frame, the only result is an open fuse. If a hot wire
shorts to an ungrounded frame, the frame itself becomes hot and poten-
tially dangerous. A fuse is a weak link in a circuit, designed to break down
before anything else does. The maximum safe current in a circuit is de-
termined by the designers. Too large a fuse can pass excessive current,
damaging expensive equipment.
• For electrical fires, use Type C, BC or ABC extinguishers only. Don’t use
soda acid or other liquid stream extinguishers. They will damage elec-
trical equipment and present a shock hazard to the user.
• Digital equipment can be easily damaged or destroyed by static charges.
Microprocessors and other integrated circuits contain tiny transistors not
much more than a millionth of an inch across, which operate at 5 to 12
volts.
• Be extremely careful when lifting heavy equipment. Follow the guidelines
below:
a. Squat to lift and lower. DO NOT bend at the waist.
b. Keep your low back bowed in while bending over.
c. Keep the weight as close to you as possible.
d. Bow your back in and raise up with your head first.
e. If you must turn, turn with your feet, not your body.
f. Never jerk or twist!
g. Put the weight down by keeping your low back bowed in.
h. Keep your feet apart, staggered if possible.
i. Wear shoes with non-slip soles.
j. Get help if you need it.
1.4 Safety

1-4 SV61831 Rev. A DA50S/DA55S/DA70S/DA75S AddressRight™ Printers Service Manual
1 • Introduction
Electrostatic Discharge (ESD) Procedures
Follow these guidelines to protect sensitive equipment from static damage:
• Always use a wrist grounding strap and anti-static mat when working on
equipment sensitive to electrostatic discharge. These items are furnished
in the ESD Field Service Kit, L-8351.
• Ground yourself before reaching into the equipment, or touching any
circuit board or other electrical component. Just touching a doorknob or
metal workbench may be enough, but the best guarantee is to turn the
machine off but leave it plugged in, and ground yourself on the chassis,
which is grounded through the three-wire power cord.
• Be careful of rugs—even a few steps can recharge you. Re-ground your-
self whenever you’ve walked away and returned to the machine. Rugs
are a major source of static buildup in the body.
• Take greater precautions as the objects you handle get smaller. A board
in the machine is better protected than one that is not plugged in; a chip
on a board is better protected than one in your hand.
• Stay away from metal conductors. The plastic and resin that chips and
boards are made of are much better insulators than metal. It’s most im-
portant to keep your hands away from any metal which contacts the data.
In particular, this means the long connector along the bottom of each
board, and the pins coming out of the chips. These signal and data lines
are directly connected to the fragile inner circuits of the chips. When han-
dling a board, try not to touch the connector; when handling a chip, try
not to touch the pins.
1.4 Safety