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Service Manual - Copy Finishing Systems

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1. o 20 Fr v VCC Stabilized and rectified 5V made from incoming 10V AC from transformer Measure between Test Point VCC and Test Point GND PGND using a voltmeter The voltage will be shown on the voltmeter Range 4 9 5 1V GND Ground is the minus when measuring 5V VCC R41 Trim Potentiometer for Contrast setting of the LCD 4 41 TEST POINTS 29 November 2006 Interlock PCB in Booklet Maker TP1 PGND TP2 UNREG IC4 esc 24V ro TP1 Incoming unregulated 36V before interlock relay Measure between Test Point TP1 and Test Point PGND using a voltmeter The voltage will be shown on the volt meter regardless of the voltage being outside allowed range 29 43V UNREG Outgoing unregulated 36V after interlock relay Measure between Test Point UNREG and Test Point PGND using a voltmeter The voltage will be shown on the voltmeter unless Voltage is outside allowed range 29 43V Voltage will be OV Machine is interlocked i e the top cover
2. 4 5 Side jogger motor Cycle time out 4 6 Side jogger motor Short Side jogger motor Open 2 Stapler motor Cycle time Stapler motor Short circuit Stapler motor Open circuit 02 0 22222 1 Set transport motor Short circuit Set transport motor Open circuit Fold roller motor No displacement pulses 4 10 Fold roller motor Short 2 1 4 11 Fold roller motor Open circuit eee esee eren 4 11 Fold knife motor Cycle time out eese 4 12 Fold knife motor Short circuit 4 4 12 Fold knife motor Open circuit 1eee esee eren enn 4 13 Fold stop gate motor Short circuit sees 4 13 Fold stop gate motor Open circuit 4 13 Staple Fold positioning motor No displacement pulses 4 14 Staple Fold positioning motor Cycle time out 4 15 Staple Fold positioning Shor
3. 6 3 O11 Fuse FS 2A E 6 3 O11 FAZA T 6 3 O11 Capacco c 6 3 O13 29 November 2006 ELECTRICAL COMPONENT LIST 6 1 1 FRONT VIEW Main Power SW LCD Panel Switches Addon PCB Interlock switch PCB Set Counter Softstart PCB CPU PCB 5 25 Qo a BM Q9 BM M6 Rectifier F2 F4 4 Transformer Capacitor 6 3 ELECTRICAL COMPONENT LIST 29 November 2006 6 1 2 REAR VIEW BM M19 MD3DC PCB H MD6DC PCB B BM Q11 MD6DC PCB Interlock PCB Collator Interface PCB BM Q37 29 November 2006 ELECTRICAL COMPONENT LIST 6 1 3 CONNECTOR VIEW Terminator Terminator Stacker 200 Power Receptacle Receptacle Line Filter vo 9 55 as F1 Collator Interlock jumper Interlock jumper Power Supply Power Supply Trimmer Squarefolder 6 5 ELECTRICAL COMPONENT LIST 29 November 2006 6 1 4 OUTFEED UPPER VIEW otaple Detection Lead Interlock Switch BM Q19 BM Q20 16 17 BM Q36 Set Counter i MHIL i i Outfeed cover removed BM Q4 BM Q8 29 November 2006 ELECTRICAL COMPONENT LIST 6 1 5 OUTFEED LOWER VIEW A lt lt 5 25
4. FTR 3 24 3 2 12 LENGTH ADJUSTMENT MOTOR M4 amp SENSOR Q12 FTR 3 25 3 2 13 LENGTH ADJUSTMENT HOME POSITION SWITCH 511 FTR 3 26 35 2 14 LOWER OUTFEED opo eate vo ipo FTR 3 27 32 10 UPPER 4OUTFEED FTR 3 28 3 2 16 TRIM BIN FULL SENSOR 08 FTR 3 29 3 2 17 TRANSMISSION 0 FTR 3 30 3 2 10 KNIFE SUPPORT CHAIN FTR 3 31 92 19 KNIFE CHAIN FTR 3 32 3 2 20 INFEED FTR 3 33 23 cel f FTR 3 35 MDODGIPODB preiero r e OO FTR 3 35 4 TROUBLESHOOTING 4 1 FAULT CODE 5 FTR 4 1 5 SERVICE TABLES 9 SERVICE TABLE Sy FTR 5 1 6 DETAILED SECTION DESCRIPTIONS 6 1 ELECTRICAL COMPONENT FTR 6 1 o ME ANREISE 6 2 INF EED VIEW 6 3 6 1 3 OUTFEED VIEW FTR 6 4 6 1 4 STOP CARRIAGE VIEW eve FTR 6 5 6 2 BOARD STL RUG URE nu T xq FTR 6 7 6 2 6 7 6 2 2 CONTROLLER MD6DOC eH Hmm FTR 6 8 6 2 2 CONTROLLER MD6DC
5. 1 TRIMMER INSTALLATION 29 November 2006 1 4 2 INSTALLATION PROCEDURE Unpacking 1 Remove all parts from the pallets 2 Ensure all of the packing material is removed from the outside of the Trimmer 3 Tilt the Trimmer to upright position ANWARNING 2 persons are required to tilt the Trimmer to the upright position 29 November 2006 TRIMMER INSTALLATION Remove the belt stacker 9 S 72 Booklet Maker 1 Loosen screws A on the Booklet Maker x 2 Disconnect the Belt stacker cable E x 1 Remove belt stacker from the Booklet maker N Secure screws X 2 TRIMMER INSTALLATION 29 November 2006 1 4 3 ADJUSTMENTS Height adjustment 1 Remove the Trimmer front cover by removing the screws x 5 2 Move the Trimmer up to the Booklet maker 29 November 2006 TRIMMER INSTALLATION Height adjustment o S 72 C D 3 Adjust the height of the Trimmer so that the docking bracket B on the Trim mer fits in the docking hole C on the Booklet maker one revolution on the nuts is 1 5mm 1 16 in height Adjust by turning the four nuts D on the Trim mer with the Multi tool NOTE Make sure that the Ground plate on the docking bracket B is ground ed correctly TRIMMER INSTALLATION 29 November 2006 F E 4 Looking from behind the s
6. 6 6 6 15 OU TREE DOW VIEW dr rx pd 6 7 INEEED UPPER VIEW 6 8 6 1 7 INFEED LOWER VIEW Fun 6 9 6 9 INFEED MODULE VIEW 6 10 6 19 STACKER MODULE VIEW 6 11 6 2 BOARD STRUG LURE tta 6 13 6 2 1 ue 6 13 6 2 2 CONTROLLER CPU 6 14 6 2 9 CONTROLLER WIDGDC a Urbs 6 15 6 24 CONTROLLER MDD cirein bred dix Ei 6 17 6 2 4 CONTROLLER MD3DC 6 18 0 3 BOOKLET MAKING PROCESS toris aiae aaa raai 6 19 PRINCIPLE OF OPERATION 6 19 6 3 2 A5 IZEADJIUSTMENT raaa Eii 6 23 SPECIFICATIONS BOOKLET MAKER BM 200 0 Spec 1 I Spec 1 SQUAREFOLDER SQF 2001 Spec 1 WIRING Wir 1 EME TRECE Wir 1 Sduatelolde dus didnt Wir 1 VIII PERIPHERALS TRIMMER FTR 200 1 INSTALLATION PROCEDURE 1 1 INSTALLATION PROCEDURE FTR 1 1 2 PREVENTIVE MAINTENANCE SCHED
7. Fault Code 040 indicates that the Pre Infeed Motor BM M19 does not receive any displace ment pulses Initial Actions Check fuse F2 on Transformer Enter the Service mode and select Pre Infeed Motor BM M19 in check motors Procedure Disconnect the sensor plug Q34 to motor BM M19 Measure between the red wire Q34 and the black wire Q34 5V and Signal ground The voltage is approximately 5 VDC Y N Disconnect plug H P14 from PCB H Measure between the J14 15 and J14 13 5V and Signal ground The voltage is approximately 5 VDC YN Replace PCB H Replace wire harness Disconnect plug H P14 from PCB Check wires for Continuity Short circuit from the white wire Q34 to H P14 14 the black wire Q34 to H P14 13 the red wire Q34 to H P14 15 Is there Continuity and no Short circuit Y N Replace wire harness 1 Replace motor BM M19 2 Replace PCB 4 19 FAULT CODE DESCRIPTIONS 29 November 2006 BM 041 Fault Code BM 041 indicates that the Pre Infeed Motor BM M19 has a Short circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M19 Run the Diagnostics again Fault code BM 042 Open circuit is displayed Y N Disconnect plug H P2 from PCB Check wires for Short circuit across leads the orange wire M19 to H P2 1 and the violet wire M19 to H P2 8 Is there Short circuit Y N Replace PCB Replac
8. Remove Crank journal F with an 17 mm open wrench Remove screw and washer amp x1 x1 Remove the Crank wheel H Remove screws 1 to the motor x3 Replacement 1 Qr Reinstall screws 1 to the motor x3 NOTE DO NOT TIGHTEN THE SCREWS Reinstall the Crank wheel H Reinstall screw and washer x1 amp x1 Tighten screws 1 to the motor x3 Reinstall Crank journal F with an 17 mm open wrench NOTE Make sure to install the smaller end J of the Crank journal Reverse the rest of the removal procedure 3 55 AREA C 29 November 2006 3 6 6 FOLD TRANSMISSION MODULE Remove Front cover 3 3 1 Disconnect connector A to Fold roller motor M6 EZ x1 Disconnect connector B to Fold roller sensor Q9 x1 p 22 Remove nuts C to the Fold transmission module amp x3 3 56 29 November 2006 AREA C 3 6 7 FOLD TRANSMISSION BELT amp SENSOR Q9 B o E d OW 6 5 lt X Continued on next page 3 57 AREA C 29 November 2006 Removal 1 2 3 3 4 Remove Fold transmission module ilf 366 Remove screws A B and C to Fold transmission plate x3 Remove the Fold transmission plate and Fold roller sensor Q9 plate D Loosen screw E x1 Remove the Fold transmission belt Replacement k 2 Reinstall Fold transmission bel
9. D5 Yellow LED flashes when power is on The flashing indicates that a program is present and functioning Should a download fail or the 5V is missing Yellow LED would be OFF o 20 Fr v 4 35 LEDS 29 November 2006 Interlock PCB in Booklet Maker PGND TP2 D9 age Mb on D6 UNREG TP1 24 7 D6 Red LED is ON when unregulated 36V is present If machine is interlocked i e the top cover is open and 36V is cut off or 36V is missing LED is OFF The unregulated 36V can be measured between UNREG Test Point and PGND Test Point D7 Red LED is ON when 24V is present If machine is interlocked i e the top cover is open LED will still be ON It will also be ON if 36V is present but not 24V In such a case the 24V stabilizing cir cuit on the Interlock PCB would be defective To establish that actual 24V is present measure between 24V Test Point and PGND Test Point D9 At power up input power is checked to be within allowed range If input volt age is too high or too low a fault is presented to the operator and machine will be inoperable If the input voltage is within allowed range the interlock relay is ac tivated When interlock relay is activated the LED D9 is ON If an interlock relay fault is detected that is presented to the operator and machine will be inoperable During normal operation the LED D9 is ON when covers are closed If a cover is open
10. 3 72 3 7 5 CPU PCB AND COLLATOR INTERFACE PCB A 3 73 270 ADDON CBF Ioan ED METRUM 3 75 IEEBA JL uim EI 3 76 39 STACKER em 3 17 38 1 STACKER MODULE 3 pes pb 3 17 3 8 2 STACKER MOTOR 3 78 3 9 BOOKLET QUALITY 3 79 3 9 1 STAPLE STOP GATE 3 79 Vi 3 9 2 SIDE GUIDE PARALLELISM esses 3 81 3 9 3 STAPLE POSITION TO CLINCHER 3 82 3 94 STAPEEIR TRESOUIE NEU 3 85 3 9 5 CLINCHER POINTS 3 86 396 CLINCHER PRESSURE it uiro 3 87 3 9 7 STAPLE AND FOLD 3 89 SESS FOLD SKEW 3 91 3 9 9 STAPLE POSITION ON SQUARE FORMED SPINE 3 92 3 10 POWER REQUIREMENT 3 93 3 10 1 TAPPING THE 3 93 TROUBLESHOOTING 4 1 DESCIIPLUGOIBNSsstassiateceioaaixue Rae pt ud Can 4 1 4 2 BLOWN FUSE CONDITIONS erem 4 31 ONE D Mc 4 33 4 4 5 55 4 39 SERVICE TABLES 5 1 SERVICE PROGRAM 5 1 5 1 1 SERV
11. Remove Stacker Module 3 8 1 Loosen nuts A x3 olide the motor bracket B and remove Disconnect connector C EZ x1 Ce X Je Remove screws D amp x3 Replacement 1 Reverse the removal procedure NOTE Stacker motor pulley is D shaped 3 78 29 November 2006 BOOKLET QUALITY ADJUSTMENT 3 9 BOOKLET QUALITY ADJUSTMENT 3 9 1 STAPLE STOP GATE PARALLELISM B pam 9 ot oy 0 65 lt X A D C Continued on next page 3 79 BOOKLET QUALITY ADJUSTMENT 29 November 2006 Purpose The purpose is to ensure that the staples are parallel to the edge of the sets Removal 1 Set the machine to A3 11x17 2 Open Top cover 3 Remove the rear stapler head 3 4 12 4 Fold an A4 8 5x11 paper lengthwise by hand and feed the paper down be tween the side guides LEF 5 Feed the paper so that the straight edge is positioned against the Staple stop gate 6 Enter the Service program 5 1 1 7 Start the Staple Fold positioning motor M9 8 Step the motor to align the straight edge A with the locating holes B in the paper path 9 The straight edge A must align with the locating holes on both sides Adjustment 1 Loosen screw C x1 2 Insert a screwdriver in the notches D rotate to align the locating holes B with the straight edge A v x1 3 Tighten the screw amp x1 4 Check ac
12. FTR 200 Trimmer Enables On line trimming Especially thicker sets gt 4 sheets look unprofessional because of creep FTR 200 will trim those edges up to 16 mm 5 8 SQF 200 SquareFolder Enables the possibility to give the booklets the perfect bound look Page intentionally blank 29 November 2006 BOOKLET MAKER INSTALLATION 1 3 BOOKLET MAKER INSTALLATION 1 3 1 ACCESSORY CHECK gt Q S 72 E F G H Check the quantity and condition of the accessories in the box against the following list Description Q ty A Communication 1 Exe CON 1 C Terminator plug will always be installed onto BM 200 1 D Terminator plug 200 1 E Interlock Jumper will always be installed onto BM 200 1 Interlock Jumper 200 1 est 1 Cable protector sticker 1 Cable 1 BOOKLET MAKER INSTALLATION 29 November 2006 1 3 2 INSTALLATION PROCEDURE Unpacking 1 Remove all parts from the pallets 2 Slide the Booklet maker off the pallet by pulling the two cardboard handles A underneath the Booklet maker straight out WARNING 2 persons are required to slide the Booklet Maker off the pallet 1 6 29 November 2006 BO
13. NOTE Make sure that the screw A is positioned against flat of the motor shaft And that the motor shaft is level F with the Bracket C Reverse the rest of the removal procedure 3 30 29 November 2006 AREA A 3 4 12 STAPLER HEAD Replacement of staple cartridge 1 2 gt A gt ot oy 7 6 5 o lt X Open the booklet maker top cover Raise the handle A on the staple cartridge locking lever Remove the staple cartridge B from the stapler head by sliding it away from the stapler head Renewing or reinstalling the staple cartridge pull 25 mm 1 inch of staples out of the cartridge and tear the staples downward against the staple tear line C The staple tear line is indicated by an arrow on the side of the cartridge Insert the cartridge into the stapler head with the end of the staples facing toward the head of the stapler mechanism Push it firmly ahead NOTE Hold the staple cartridge firmly in place and push down the cartridge locking lever A Close the top cover Hand feed a four sheet set of paper The booklet maker will automatically cycle and advance staples until both staple heads are driv ing staples If not and or if error message persists repeat procedure Continued on next page 3 31 AREA A 29 November 2006 E D Removal of stapler head 1 2 3 Open the booklet maker top cover Disconnect the staple indication lead D fr
14. Removal Back jogger module 1 Remove Infeed module 3 4 1 2 Remove Infeed transport module 3 4 3 3 Remove the screw to plastic distance C x1 4 Unhook the Length adjustment strap wheel D NOTE DO NOT TURN THE ADJUSTMENT SCREW 5 Insert a screwdriver E in the shaft and unscrew the shaft F to the Back jog ger module v x1 NOTE Rotate the screwdriver counterclockwise to unscrew the shaft 6 Remove the shaft F 7 Remove the Back jogger module NOTE If removing the Back jogger module completely remove three cable ties to the Infeed sensor Q1 harness Replacement Back jogger module NOTE When replacing the Back jogger module make sure that the Back jogger fingers G and the Infeed bearing bracket H is in its right position 1 Reverse the removal procedure 3 27 AREA A 29 November 2006 3 4 10 BACK JOGGER FINGERS C B AA 2 D F P Continued on next page 3 28 29 November 2006 AREA A EO EN d Removal 1 2 Remove Back jogger module 3 4 9 Loosen spring A with a screwdriver B by pulling the screwdriver straight out according to the arrows C v x1 pa ot 7 6 5 o lt X Remove screws 0 x2 Remove E clips E x4 Pull out the Back jogger arm shaft F NOTE Make sure to notice the orientation of the Back jogger fingers C H I and J a
15. 2 Lubricate where needed 1 Lubricate where needed 2 Replace motor BM MO9 BM 026 Fault Code BM 026 indicates that the Staple Fold positioning motor BM M9 has a Short circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M9 Run the Diagnostics again Fault code BM 027 Open circuit is displayed Y N Disconnect plug B P2 from PCB B Check wires for Short circuit across leads the orange wire M9 to B P2 10 violet and the violet wire M9 to B P2 3 orange Is there Short circuit Y N Replace PCB Replace wire Harness Replace motor 9 4 15 FAULT CODE DESCRIPTIONS 29 November 2006 BM 027 Fault Code BM 027 indicates that the Staple Fold positioning motor BM M9 has an Open circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M9 Enter Service mode and start Staple Fold positioning motor BM M9 in check motors Measure between the orange wire M9 and the violet wire M9 PWM 36V and ground The voltage is approximately 36 VDC Y N Disconnect plug B P2 from PCB Measure between J2 3 and J2 10 PWM 36V and ground The voltage is approximately 36 VDC Y N Replace PCB Replace wire Harness Replace motor BM 031 Fault Code BM 031 indicates that the stopgate solenoid has an Open circuit Initial Actions Make sure that the connectors are properly connected to the Solen
16. 3 45 3 5 1 STAPLE STOP GATE SOLENOID 3 45 3 5 2 STAPLE STOP GATE RELEASE SOLENOID SOL2 3 46 3 5 3 SADDLE STAPLING START SENSOR 3 48 9 5 eet 3 49 3 6 1 STAPLE FOLD POSITION MOTOR M9 amp SENSOR Q10 3 49 3 6 2 LENGTH TRANSMISSION SHAFT amp SENSOR Q11 3 50 3 6 3 FOLD STOP GATE MOTOR amp SENSOR 7 3 52 94 FOLD STOP GATE ca 3 53 3 6 5 FOLD KNIFE MOTOR M7 SENSOR Q15 3 54 3 6 6 FOLD TRANSMISSION 3 56 3 6 7 FOLD TRANSMISSION BELT 8 SENSOR Q9 3 57 3 6 8 FOLD ROLLER MOTOR 6 3 59 3 6 9 FOLD TRANSMISSION GEAR 55 3 61 3 6 10 FOLD DISTANCE 3 62 9o JT UPPER FOLDER ROLLER 3 63 3 6 12 LOWER FOLDER 3 65 OUT PEED SENSOR enean s intei M 3 67 TENTE 3 69 3 69 3 7 2 ME KE 3 70 LOWER MDODO O omino E 3 71 374 INTERLOCK POB E krcnn a
17. C Replace wire Harness Replace motor BM M3 4 6 29 November 2006 FAULT CODE DESCRIPTIONS BM 010 Fault Code BM 010 indicates that the Side jogger motor BM M3 has an Open circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M3 Enter Service mode and start Side jogger motor BM M3 in check motors Measure between the orange wire M3 and the violet wire M3 PWM 36V and ground The voltage is approximately 36 VDC Y N Disconnect plug C P2 from PCB Measure between J2 2 and J2 9 PWM 36V and ground The voltage is approximately 36 VDC Y N Replace PCB Replace wire Harness Replace motor BM M3 o 50 22 Fr v 4 7 FAULT CODE DESCRIPTIONS 29 November 2006 BM 011 Fault Code BM 011 indicates that the Stapler motor BM M4 had a Cycle time out Initial Actions Check fuse F2 on Transformer Enter the Service mode and select Stapler motor BM M4 in check motors Make sure that the Stapler home position sensor BM Q14 is installed correctly Procedure Enter the Service mode and select Stapler home position sensor BM Q14 in check sensors The Stapler home position sensor indicates 1 when the sensor is blocked and 0 when the sensor is unblocked Y N 1 Replace sensor BM Q14 2 Disconnect plug C P13 from PCB Measure between J13 7 and J13 9 5V and ground The voltage is approximately 5 VDC Y N Replace PCB C D
18. J B B F 1 H E D C Continued on next page 3 63 AREA C 29 November 2006 Removal 1 Remove outfeed cover 3 3 4 2 Remove the paper guide A by pressing it against the rear side of the Booklet maker 3 Loosen springs B to the Cams to the Upper folder rollers 4 Remove Fold distance bracket Il 3 6 10 5 Remove nuts C and bearing brackets D on the front and rear side of the booklet maker amp x2 6 Remove springs E on the front and rear side of the Booklet maker 7 Remove bearings F x2 on the rear side of the Booklet maker NOTE Bearings on the rear side are secured with screws and washers x2 x2 At the front side of the folder rollers there is a trans verse hole through the axle journal in which an allen key can be insert ed to facilitate removal of the screws 8 Gently remove the Upper folder rollers Adjustment 1 Insert a 0 2 mm feeler gauge between the Upper folder rollers G to ensure 0 2 0 05 mm gap G between the Upper folder rollers If not go to step 2 2 Loosen nuts on the front and rear side of the booklet maker amp x2 3 Adjust eccenter on the front and rear side of the Booklet maker according to step 1 4 Tighten nuts H amp x2 5 After tightening nuts H recheck the distance between the Upper folder rollers G 6 Lubricate with Molybdenum grease on the upper side J of the
19. LED D9 is OFF Note that the fault codes are only visable in operator mode 4 36 29 November 2006 LEDS Coollator Interface PCB in Booket Maker 17014 O C 2 M TINA D OUT IC8 R3 Er IC14 IC15 d EN rm BT bee UH D8 07 06 05 04 03 D2 01 09 010 D11 012 013 014 015 016 D1 D8 are signals from BM 200 D9 D16 are signals from Collator gt c o0 D5 8 and D11 D16 Not used D1 Connection detect Power on BM 200 is switched on Docking sensor is acti vated machines are docked BM 200 indicates connection to Collator D2 opeed regulation 1800 sph D3 opeed regulation 1500 sph D2 D3 Speed regulation 1000 sph D4 Hard stop Collator stops immediately D9 Cycle up signal from collator D10 Check set signal Note The LED illuminates throughout the duration of the signal 4 37 Page intentionally blank 29 November 2006 TEST POINTS 4 4 TEST POINTS Motor Drive PCB MD6DC in Booklet Maker amp Trimmer UNREG 2 0 TEJI i E m H mr r dl e a Med sn L E F HE _ gt c o0 UNREG Outgoing unregulated 36V after interlock relay Measure between Test Point UNREG and Test Point GND PGND using a voltmeter The voltage will be shown on the voltmeter unless Voltage is outside allowed range 29 43V Voltage will
20. M ELSE E 6 4 G16 PCB p CR 6 4 15 AUOOU SE aciertos ner Omer ar er ha 6 3 O17 PCB ee E 6 3 N10 PCB VEN 3 J3 6 1 ELECTRICAL COMPONENT LIST 29 November 2006 Page Grid code Communication Gollator rac pror Udo s cubano ee eS CY ER aes 6 5 L10 Stacker Recebtacl6e UPS SEA DICE NUS 6 5 A18 EET TT ILLU T S 6 5 N5 PUMP sse 6 5 15 Terminator Communication eene nennen nnn nnn nnn nns 6 5 N4 Interlock jumper Power supply 1 44 4222 6 5 iis M18 Power supply Squarefolder 5 ie tone Some vec ee ees 6 5 T26 FUSE FE te 6 5 O8 Power Receptacle Line Filter A cba oS x Ev aa E Ex Yu DN 6 5 O7 SOU 6 3 6 6 G20 sare cS 6 3 N6 Panel SWIEICIIGS 6 3 O6 Mail DOWER 6 3 O9 PRE DETIENE 6 3 O12 TRATY STORING Ne TC eae Soe E S ET 6 3 O10 FZ TOA
21. 1 Removal 1 Enter service mode ee 51 2 Note all EEPROM values Index 1 26 MB 5 1 2 EEPROM values 3 Remove Front cover 3 3 1 4 Remove all connectors from the CPU and Collator Interface x9 5 Squeeze the barbs of the pins and remove CPU and Collator Interface PCB Replacement 1 Install the EEPROM C on the new CPU PCB NOTE If the EEPROM is changed or broken you have to manually type in the EEPROM values you previously noted fllff 5 1 1 Changing EEP ROM values 2 Reinstall the CPU PCB 3 Reconnect all connectors to the CPU PCB x9 4 Reinstall Protection plate and tighten screws A 2 5 Reinstall Front cover pr 3 3 1 Adjustment 1 If you do not have the EEPROM values or EEPROM is corrupted perform the EEPROM reset followed by Paper size reset 3 5 4 3 74 29 November 2006 PCB 3 7 6 ADDON PCB F i F P2 e F P6 x bx E b pa ot oy 7 6 5 o lt X F P5 CAUTION ESD Hazard ESD Electrostatic Discharge can cause software crashes data and or communications problems Failure to use proper ESD pro cedures will cause damage to electronic components example PCBs ESD problems can be minimized by maintaining all machine ground con nections ensuring the proper handling of circuit boards and sensors Use ESD protection when working near PCBs Failure to
22. 1 J Ground strap and 1 K Cable 6 ke 2101 0 1 L Cable protector 1 M Cable Nolde a ascsceccccensineessasaacsananseeansansdvebapahaaceanseansunemncnsanes 1 1 23 SQUAREFOLDER INSTALLATION 29 November 2006 1 5 2 INSTALLATION PROCEDURE Unpacking 1 Remove all parts from the pallets 2 Ensure all of the packing material is removed from the outside of the Square Folder 3 Tilt the SquareFolder to upright position 29 November 2006 SQUAREFOLDER INSTALLATION Remove the belt stacker D o d ES S 72 Trimmer inside view Disconnect the Power cord to the Booklet Maker x 1 Loosen screws A amp x 2 securing the Belt Stacker on the Trimmer Disconnect the Belt stacker cable E x 1 from the Trimmer Remove the Belt stacker from the Trimmer Secure screws A on the Trimmer Remove the positioning pins from the upper holes B used for the belt stacker x 2 Using the lower hole C install the Ground strap to the inside of the position a ing pin E using the 25 mm washer and screw provided gt x 1 P x 1 Install the other end of the ground strap to the rear frame D amp x 1 torx Using the second lower hole install the other positioning pin using
23. 36 VDC Y N Disconnect plug B P2 from PCB Measure between J2 1 and J2 8 PWM 36V and ground The voltage is approximately 36 VDC Y N Replace PCB Replace wire Harness Replace motor 1 4 3 FAULT CODE DESCRIPTIONS 29 November 2006 BM 004 Fault Code BM 004 indicates that the Back jogger motor BM M2 had a Cycle time out Initial Actions Check fuse F2 on Transformer Enter the Service mode and select Back jogger motor BM M2 in check motors Make sure that the Back jogger home position sensor BM Q3 is installed correctly Procedure Enter the Service mode and select Back jogger home position sensor BM Q3 in check sensors The back jogger home position sensor indicates 1 when the sensor is blocked and 0 when the sensor is unblocked Y N 1 Replace sensor BM Q3 2 Disconnect plug C P13 from PCB Measure between J13 1 and J13 3 5V and ground The voltage is approximately 5 VDC Y N Replace PCB Disconnect plug from sensor BM Q3 Check wire for Continuity Short circuit from the white wire Q3 to C P13 2 Is there Continuity and no Short circuit Y N Replace wire Harness Connect plug C P13 to PCB C Measure between the red wire Q3 and the black wire Q3 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness Replace PCB Turn motor BM M2 one and a half turn in both directions by hand You should be able to use about t
24. 4 28 BM 207 BM Q7 Fold stop sensor was Not blocked within timeout 4 28 BM 208 BM Q7 Fold stop sensor was Blocked exceeding timeout 4 28 BM 209 BM Q8 Outfeed sensor was Not blocked within timeout 4 29 BM 210 BM Q8 Outfeed sensor was Blocked exceeding timeout 4 29 BM 401 4 29 ST 001 ST M1 Stacker motor Short circuit 1112211 4 30 ST 002 ST M1 Stacker motor Open 4 30 CAUTION ESD Hazard ESD Electrostatic Discharge can cause software crashes data and or com munications problems Failure to use proper ESD procedures will cause damage to elec tronic components example PCBs ESD problems can be minimized by maintaining all machine ground connections ensuring the proper handling of circuit boards sensors Use ESD protection when working near PCBs Failure to use ESD protection is likely to result in a PCB failure 3 1 29 November 2006 FAULT CODE DESCRIPTIONS BM 001 Fault Code BM 001 indicates that the Infeed motor BM M1 does not receive any displacement pulses Initial Actions Check fuse F2 on Transformer Enter the Service mode and select Infeed motor BM M1 in check motors Procedure Disconnect the sensor plug Q2 to motor BM M1 Measure between the red wire Q2 and the black wir
25. 6 9 6 3 TRIMMING 5 1 nnne nnns FTR 6 11 6 3 1 PRINCIPLE OF OPERATION 000 0 FTR 6 11 6 3 2 SIZE ADJUSTMENT U RE GE ted ei dose aa FTR 6 13 632 SIZE ADJUSTMENT decia te FTR 6 14 SPECIFICATIONS SPECIFICATIONS duc n Ed d ETE FTR Spc 1 WIRING RR 1 PERIPHERALS Squarefolder SQF 200 1 INSTALLATION PROCEDURE 14 SINS TALEATION PROGEDUFTRE SQF 1 1 2 PREVENTIVE MAINTENANCE SCHEDULE 2 1 PREVENTIVE MAINTENANCE SCHEDULE SQF 2 1 3 REPLACEMENT AND ADJUSTMENT COVER SQF 3 1 HEROIN MIN zo E MM SQF 3 1 REAR COVER Ent SQF 3 2 2159 INFEED COVER ee Rt PT SQF 3 3 Sq gt OU LTREED SQF 3 4 319 TOP COVER qn SQF 3 6 92156 MLT THE MACHINE cerren a SQF 3 7 I MOTOR Pre SQF 3 9 3 2 1 TRANSPORT BELT MOTOR 1 SQF 3 9 322 STOP GATE MOTOR AMA SQF 3 10 9 232 CLAMP MOTOR M3 ebrei In ai aue SQF 3 11 3 24 ROLLER MOTOR M4 AND PRESSURE ROLLER SQF 3 12 39 SENSORSAND SWITCHE Docet bote Sce ates SQF 3 15 3 3 1 STOP GATE SENSOR 1 teens SQF 3 15 3 3 2 ROLLER MOTOR FRONT R
26. DESCRIPTIONS BM 025 Fault Code BM 025 indicates that the Staple Fold positioning motor BM M9 had a Cycle time out Initial Actions e Check fuse F2 on Transformer Enter the Service mode and select Staple Fold positioning motor BM M9 in check motors sure that the Staple Fold home position sensor BM Q11 is installed correctly Procedure Enter the Service mode and select Staple Fold home position sensor BM Q11 in check sensors The Staple Fold home position sensor indicates 1 when the sensor is blocked and 0 when the sensor is unblocked Y N 1 Replace sensor BM Q11 2 Disconnect plug B P13 from PCB Measure between J13 4 and J13 6 5V and ground The voltage is approximately 5 VDC Y N Replace PCB B Disconnect plug from sensor BM Q11 Check wires for Continuity Short circuit from the white wire Q11 to B P13 5 Is there Continuity and no Short circuit Y N Replace wire Harness Connect plug B P13 to PCB B Measure between the red wire Q11 and the black wire Q11 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness o 50 5 8 Fr v Replace PCB Turn the length transmission shaft by hand Are you able to turn the shaft Y N Lubricate shaft 3 6 2 Pull the length adjustment strap 3 4 1 Item down towards Stapler motor BM M4 Does it move easily Y N 1 Make sure that nothing interferes with the movement
27. Input 4 21 BM 151 36V Input 36V Input nennen 4 22 BM 152 36V Output 36V Output 4 22 BM 153 36V Output 36V Output Low 4 23 BM 154 24V Output 24V 4 23 BM 155 24V Output 24V LOW nixa Ed Ge Sed ne tinc 4 24 BM 156 516 517 Interlock switch Booklet maker is Faulty 4 24 BM 157 36V Output 36V Output relay 4 25 BM 158 Com Communication 4 25 159 MD6DC Not connected 4 26 BM 160 PCB MD6DC Not connected eere 4 26 BM 161 PCB PCB MD3DC Not connected 4 26 BM 201 BM Q1 Paper infeed sensor was Not blocked within timeout 4 27 BM 202 BM Q1 Paper infeed sensor was Blocked exceeding timeout 4 27 BM 203 BM Q4 Start sensor Saddle stapling was Not blocked within timeout 4 27 BM 204 BM Q4 Start sensor Saddle stapling was Blocked exceeding timeout
28. Y N Replace wire Harness Measure between the red connector on the Rectifier and P6 1 on interlock PCB Is there continuity Y N Replace wire harness Replace interlock PCB 4 21 FAULT CODE DESCRIPTIONS 29 November 2006 BM 151 Fault Code BM 151 indicates that the 36V input is low Initial Actions Check fuse F3 Check Voltage protection plug P7 on the interlock PCB The resistance must be grater than MOhm Make sure that contact P8 on interlock PCB is correctly installed Make sure that contact P12 on controller PCB is correctly installed Make sure that the transformer in the machine is wired correctly Procedure Measure incoming voltage on Rectifier White and Blue The voltage is approximately 26V Y N Replace transformer Measure outgoing voltage on rectifier Red and Black The voltage is approximately 36V Y N Replace Rectifier Power off the machine Measure between the black connector on the Rectifier and P6 3 on interlock PCB Is there continuity Y N Replace wire Harness Measure between the red connector on the Rectifier and P6 1 on interlock PCB Is there continuity Y N Replace wire harness Replace interlock PCB BM 152 Fault Code BM 152 indicates that the 36V output is high Procedure Power on machine and close covers Measure between P6 1 and P6 3 on the interlock PCB The voltage is approximately 36V Y N The voltage is more than 43V Y N The voltage is less th
29. a 35 sheet should pass quickly switch off the power in order to avoid jam clearence If set passes go to item 7 If set is stopped adjustment is concluded Loosen screw D Turn screw E slightly clockwise Thighten screw D Go to item 6 3 44 29 November 2006 AREA B 3 5 3 5 1 STAPLE STOP GATE SOLENOID SOL1 o 9 ot oy o 6 5 o lt 4 The purpose is to ensure adequate engagement of the pressure rollers NOTE This adjustment interacts with 3 4 19 Perform adjustment 3 4 19 before this adjustment 3 5 1 Removal 1 Check Adjust the Pressure roller li 3 4 19 2 Setthe machine to A3 11x17 3 Remove Infeed cover 3 3 2 Adjustment 1 Enter service mode and activate the SOL1 in check solenoids 5 1 1 5 1 2 NOTE The solenoid will be activated for approximately 30 seconds 2 Check that distance A is 26 mm NOTE Use a sliding caliper to measure the distance from paper path to the top of the pressure roller When SOL 1 is activated If not go to step Make sure that the right and left Drive roller contacts the Pressure roller at the same time If not form the Drive rollers to obtain adjustment 3 Loosen screws C x2 4 Activate the SOL 1 again and adjust according to step 2 5 Tighten screws C x2 Replacement 1 Reverse the removal procedure 3 45 AREA B 29 November 2006 3 5 2 STAPLE STOP GATE RELE
30. ad justing sidewise Push Stapler head bracket upwards while adjusting lengthwise When correct position is obtained tighten screws and B x2 NOTE First tighten screw F while pushing Stapler head bracket upwards Secondly tighten screw B while pushing Stapler head bracket against screw A Repeat procedure for the other Stapler head Remove Tool I Reinstall Infeeder gi 3 3 3 Install new stapler heads Repeat Checking Adjustment IK Loosens screws B and F 2 Turn Screw maximum 1 8 of a revolution 45 NOTE Turn clockwise if adjusting stapler assembly downwards and vice versa Tighten screws F and B 2 NOTE First tighten screw while pushing Stapler head bracket upwards Secondly tighten screw B while pushing Stapler head bracket against screw Repeat Checking Adjustment NOTE This procedure may need to be performed several times before a good staple result is achieved Staple deformed Sidewise 25 Repeat step 6 20 regarding the sidewise adjustment NOTE Do not loosen screw F this time 3 84 29 November 2006 BOOKLET QUALITY ADJUSTMENT 3 9 4 STAPLER PRESSURE 70 0 3 mm pz HE 0 E d OW amp 5 o 85 X Removal Front 1 Remove Infeed 3 3 2 2 Remove Stapler heads 3 4 12 3 Check adjust the Clincher Pressure Gg 3 9 6 4 Rotate the motor linkage A to the down dead ce
31. be OV Machine is interlocked i e the top cover is open Voltage will be OV VCC Stabilised and rectified 5V made from incoming 10V AC from transformer Measure between Test Point VCC and Test Point GND PGND using a voltmeter The voltage will be shown on the voltmeter Range 4 9 5 1V GND PGND Ground Power Ground is the minus when measuring either unregu lated 36V UNREG or 5V VCC 4 39 TEST POINTS 29 November 2006 Motor Drive PCB MD3DC in Booklet Maker VCC RN3 RNS RN RN9 IRN10 alalslelelslslslelelelell s 2 a EET M R34 2 VCC Stabilized and rectified 5V made from incoming 10V AC from transformer Measure between Test Point VCC and Test Point GND PGND using a voltmeter The voltage will be shown on the voltmeter Range 4 9 5 1V GND PGND Ground Power Ground is the minus when measuring 5V VCC 4 40 29 November 2006 TEST POINTS CPU PCB in Booklet Maker
32. blocked Y N Go to BM 035 fault code Make sure that nothing interferes with the paper path BM 207 Fault Code BM 207 indicates that during a run the Fold stop sensor BM Q7 was not blocked within timeout Initial Actions Check fuse F2 on Transformer Make sure that the Fold stop sensor BM Q7 is installed correctly Ensure that the Fold stop sensor BM Q7 is clean Procedure Enter the Service mode and select Fold stop sensor BM Q7 in check sensors Block then unblock the BM Q7 with a sheet of paper The Fold stop sensor BM Q7 sensor indicates 0 when the sensor is blocked and 1 when the sensor is not blocked Y N Go to BM 038 fault code Make sure that nothing interferes with the paper path BM 208 Fault Code BM 208 indicates that at initialization or during a run the Fold stop sensor BM Q7 was blocked exceeding timeout Initial Actions Check fuse F2 on Transformer Make sure that the Fold stop sensor BM Q7 is installed correctly e Ensure that the Fold stop sensor BM Q7 is clean Procedure Enter the Service mode and select Fold stop sensor BM Q7 in check sensors Block then unblock the BM Q7 with a sheet of paper The Fold stop sensor BM Q7 sensor indicates 0 when the sensor is blocked and 1 when the sensor is not blocked Y N Go to BM 038 fault code Make sure that nothing interferes with the paper path 4 28 29 November 2006 FAULT CODE DESCRIPTIONS BM 2
33. by this procedure it is advised to set Index 16 FTR 200 Knife Zero in order to make sure that this specific Trimmer is set up correctly for this specific Booklet maker 1 4 5 5 12 29 November 2006 SERVICE PROGRAM MODE 5 2 SOFTWARE DOWNLOAD 5 2 1 Downloading to upper PCB MD6DC B in Booklet maker CAUTION ESD Hazard ESD Electrostatic Discharge can cause software crashes data and or communications problems Failure to use proper ESD pro cedures will cause damage to electronic components example PCBs ESD problems can be minimized by maintaining all machine ground con nections ensuring the proper handling of circuit boards and sensors Use ESD protection when working near PCBs Failure to use ESD protection is likely to result in a PCB failure 3 1 owitch Off the Main Power Switch Remove Rear Cover 3 3 1 Make sure all DIP switches 1 4 is set to OFF down position Run the BM 200 MD6DC v1 00 exe file v1 00 is an example use latest version and follow the instruction in the program or according to the latest bulletin gt xe P NOTE A red LED on the board will flash while downloading When download is complete LED goes out 5 13 SERVICE PROGRAM MODE 29 November 2006 5 2 2 Downloading to lower PCB MD6DC C in the Booklet maker CAUTION ESD Hazard ESD Electrostatic Discharge can cause software crashes data and or communications problems Failure to use pro
34. connector A x1 3 Remove nuts B to Interlock box amp amp x2 4 Remove screws C to Switch PCB x2 Replacement 1 Reverse the removal procedure Adjustment 1 Check that the Top cover is correctly adjusted 3 3 5 2 Loosen nuts B to Interlock box x2 3 Adjust the Interlock box so that Top cover activates interlock switch 2 mm 0 64 before closing 4 Tighten nuts B to Interlock box x2 5 Recheck step 3 Overriding or cheating the interlock allows the BM 200 system to operate with the top cover open which can result in personal injury Never give the o Page intentionally blank 29 November 2006 AREA A 3 4 3 4 1 INFEED MODULE Replacement Adjustment Remove Front and Rear 3 3 1 Remove Infeed cover 3 3 2 Remove connectors EZ x2 Unhook of the length adjustment strap B Remove screws C on the Front side of the Booklet maker x2 Remove screws D on the Rear side of the Booklet maker x2 1 2 3 4 9 6 7 Pull out the Infeeder carefully NOTE Make sure that the Side jogger motor M3 is not catching the frame of the Booklet maker 3 17 AREA A 29 November 2006 3 4 2 PAPER INFEED SENSOR B A 1 Remove Infeed Module egi 3 4 1 2 Remove screw A x1 NOTE You do not have to remove the Infeed module to reach the screw you are able to r
35. is open Voltage will be OV 24V Stabilised 24V made from incoming unregulated 36V before interlock relay Measure between Test Point 24V and Test Point PGND using a voltmeter The volt age will be shown on the voltmeter Range 23 25V PGND TP2 Power Ground is the minus when measuring either unregulated 36V UNREG or 24V 24 4 42 29 November 2006 TEST POINTS Addon PCB in Booklet Maker ole Os 12 METI Mo Pug NN ul 59 sista ra RN N B 2 45 olla fa 12 Z 010 e QJ 2 ze 10 SC GND o 50 8 8 Fr v GND PGND Ground Power Ground is the minus 4 43 Page intentionally blank 29 November 2006 SERVICE PROGRAM MODE 5 SERVICE TABLES CAUTION Never turn off the main power when motors are cycling To avoid damaging the circuitry stop the motor motors running under the Check Motors menu and then switch the main power off 5 1 SERVICE PROGRAM MODE 9 1 1 SERVICE PROGRAM MODE OPERATIONS The Service Program SP mode is used to check electrical data check electrical components and adjust values One service program mode is provided and controlled from the UI User Interface on the booklet maker Peripheral units are embedded in this service program Where applicable a sub menu appears after a function
36. procedure 1 Switch off the main power switch 2 Make sure the power cord connects the machine to the wall outlet The power cord and wall outlet must have ground 3 Connect the claw end of the grounding cord to a chassis ground such as earth wires screwed to chassis ground unpainted frame or an unpainted bracket secured to the frame 4 Connect the snap end of the blue cord to the snap on the adjustable wrist strap 5 Place the adjustable wrist strap securely on the wrist Wait for one minute to let the electrostatic be discharged from your body 6 ESD sensitive components can now be handled without causing any ESD re lated damage 7 New replacement PCBs and ESD sensitive components as well as old defec tive PCBs should be handled during unpacking and repacking using the ESD ground strap During the transfer from or to the packaging material the PCB should be placed on the ESD bag the replacement PCB came in CAUTION ESD Hazard ESD Electrostatic Discharge can cause software crashes data and or communications problems Failure to use proper ESD proce dures will cause damage to electronic components example PCBs ESD problems can be minimized by maintaining all machine ground connec tions ensuring the proper handling of circuit boards sensors refer to this procedure 3 1 Use ESD protection when working near PCBs Failure to use ESD protec tion is likely to result in a PCB failure 3 1 Page intentionall
37. selected f changing to a longer paper size where the total length is longer but less than 30 mm staple fold positioning motor BM M9 runs opposite the direction of the new paper size for a bit Then the motor BM M9 reverses and runs in the direc tion towards the new paper size Staple fold positioning sensor BM Q10 counts pulses from the previous paper size to the new paper size and stops the motor BM M9 when correct amount of pulses are received Staple stop and fold stop are now in correct position corresponding to the new paper size selected f changing to a shorter paper size staple fold positioning motor BM M9 runs in the direction towards the new paper size The motor BM M9 passes new selected paper size Then the motor BM M9 reverses and runs in the direction towards the new paper size Staple fold positioning sensor BM Q10 counts pulses from the previous paper size to the new paper size and stops the motor BM M9 when correct amount of pulses are received Staple stop and fold stop are now in correct position corresponding to the new paper size selected If paper jam occurs If jam occurs side jogger motor BM M3 starts oide jogger motor BM M3 moves side guides to the widest paper size to ease the removal of jammed papers Side jogger motor BM M3 stops when side jogger home position sensor BM Q13 is activated When top cover has been opened jammed papers removed and top cover closed a counter f
38. start sensor BM Q4 is clear whatever comes first M5 SOL1 as Q19 Q20 SOL2 Q4 6 21 BOOKLET MAKING PROCESS 29 November 2006 Q1 Folding Folder roller motor BM M6 that drives the first and second pair of fold rollers starts about the time when the start sensor BM Q4 is activated Also the fold stop gate motor BM M8 moves the fold stop away a bit at that time Slightly after the fold stop sensor BM Q7 is activated the fold stop gate motor 8 jogs the set upwards into position Slightly after that the fold knife motor BM M7 cycles The fold knife pushes the center of the set up through the first pair of fold rollers The fold knife motor will complete its cycle and stop in the lower position when the fold knife home position sensor BM Q15 activates A booklet is now formed When the book lets leading edge the spine is about to enter the second pair of fold rollers the fold roller motor BM M6 stops for a short time and then starts again The time the booklet sits between the second pair of fold rollers depends on the speed the delay between each set of the collator The longer it sits the more compressed the spine becomes resulting in a flatter booklet When the set is exiting the second pair of fold rollers the outfeed sensor BM Q8 activates When the trail edge of the set exits the booklet maker the outfeed sensor BM Q8 becomes clear Belt stacke
39. the 25 mm washer and screw provided gt x 1 P x 1 1 25 SQUAREFOLDER INSTALLATION 29 November 2006 Extended trim bin 1 Remove the existing trim bin from the Trimmer This trim bin can not be used together with the SquareFolder 2 Assemble the new extended trim bin A with the four screws and nuts from the installation kit x 4 amp x 4 1 26 29 November 2006 SQUAREFOLDER INSTALLATION 1 5 3 ADJUSTMENTS Height adjustment amp 72 1 Remove the front cover of the SquareFolder by removing the screws x 5 2 Move the SquareFolder up to the Trimmer 1 27 SQUAREFOLDER INSTALLATION 29 November 2006 SquareFolder Trimmer D SquareFolder front view SquareFolder rear view 3 Adjust the height of the SquareFolder so that the positioning pins B on the Trimmer fits in the docking holes C on the SquareFolder Adjust by turning the four nuts D on the SquareFolder with the Multi tool one revolution on the nuts is 1 5mm in height Adjust on the front and rear side NOTE The Multi Tool is located behind the rear cover of the BM 200 Fx 5 1 28 29 November 2006 SQUAREFOLDER INSTALLATION Parallellity adjustment 9 amp 72 F E 4 Looking from behind the system make sure that the SquareFolder is parallel to the Trimmer E 2mm If necessary adjust by turning the two nuts F on the outfeed s
40. the black wire Q9 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness Replace PCB 4 10 29 November 2006 FAULT CODE DESCRIPTIONS BM 017 Fault Code BM 017 indicates that the Fold roller motor BM M6 has a Short circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M6 Run the Diagnostics again Fault code BM 018 Open circuit is displayed Y N Disconnect plug C P3 from PCB Check wires for Short circuit across leads the orange wire to C P3 3 violet and the violet wire M6 to C P3 2 orange Is there Short circuit Y N Replace PCB Replace wire Harness Replace motor BM M6 BM 018 Fault Code BM 018 indicates that the Fold roller motor BM M6 has a Open circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M6 Enter Service mode and start Fold roller motor BM M6 in check motors Measure between the orange wire M6 and the violet wire M6 PWM 36V and ground The voltage is approximately 19 VDC Y N Disconnect plug C P3 from PCB Measure between J3 2 and J3 3 PWM 36V and ground The voltage is approximately 19 VDC Y N Replace PCB o 50 22 Fr v Replace wire Harness Replace motor BM M6 4 11 FAULT CODE DESCRIPTIONS 29 November 2006 BM 019 Fault Code BM 019 indicates that the Fold knife motor BM M7 had a Cycle time out Ini
41. the motor bracket x3 NOTE The sensor Q10 is located on the motor 5 Remove Joint 3 49 AREA C 29 November 2006 3 6 2 LENGTH TRANSMISSION SHAFT amp SENSOR Q11 e Gre as C A View on Length adjustment shaft with Rear cover removed Continued on next page 3 50 29 November 2006 AREA C Removal Sensor Q11 1 Remove Rear cover 3 3 1 2 Remove Infeed cover 3 3 2 3 Disconnect connector A x1 4 Remove sensor Q11 B Replacement Sensor Q11 1 Reverse the removal procedure ot oy 77 6 5 lt Lubricate Length transmission shaft 1 Remove Rear cover Ilf 33 1 2 Remove Infeed cover lf 3 3 2 3 Lubricate with grease on the Length transmission shaft C and the nut to the Length transmission shaft NOTE You should be able to turn the length adjustment shaft by hand 3 51 AREA C 29 November 2006 3 6 3 FOLD STOP GATE MOTOR M8 amp SENSOR Q7 si A B C D Removal 1 2 3 4 5 Set the machine to A3 11x17 Disconnect connector A EZ x1 Loosen allen screw B and remove the linkage amp x1 Remove screws C to the motor x3 Remove screw and washer D to the ground strap x1 x1 Replacement 1 2 3 Reinstall screw and washer D to the ground strap x1 x1 Reinstall screws C to the motor x3 Reinstall linkage and t
42. the side guides If you are using longer screws you may damage the side guide shaft Adjustment 1 Adjust Side guide parallelism 3 9 2 3 22 29 November 2006 AREA A 3 4 7 SIDE JOGGER MOTOR M3 amp SENSOR 012 A C 43 lt B Removal 1 Remove Infeed module 6 3 4 1 2 Remove connectors x2 3 Loosen allen screw B to pulley amp x1 4 Remove screws C to motor bracket amp x2 5 Remove Side jogger motor M3 amp sensor Q12 NOTE The sensor Q12 is located on the motor Replacement 1 Push the pulley down to make sure that it is in the right position 2 When installing the motor make sure that the allen screw is positioned against the flat D of the motor shaft 3 Reverse the rest of the removal procedure 3 23 AREA A 29 November 2006 3 4 8 SIDE GUIDE TRANSMISSION amp SENSOR Q13 A E 1 1 UL CNN Cut ee XC G D F IH Continued on next page 3 24 29 November 2006 AREA A Removal Sensor Q13 1 Remove Infeed module 3 4 1 2 Disconnect connector A to sensor Q13 x1 NOTE Make sure that the side guides are in there most inner position and move the Back jogger module by hand to make it easier to get to the sensor Replacement 1 Reverse the removal procedure o0 lt Removal Side guide transmiss
43. to ON according to picture 4 Reinstall Rear cover 3 3 1 3 69 PCB 29 November 2006 3 7 2 UPPER MD6DC PCB B 4 B P5 12 11 B P3 B P13 B P2 B P14 CAUTION ESD Hazard ESD Electrostatic Discharge can cause software crashes data and or communications problems Failure to use proper ESD pro cedures will cause damage to electronic components example PCBs ESD problems can be minimized by maintaining all machine ground con nections ensuring the proper handling of circuit boards and sensors Use ESD protection when working near PCBs Failure to use ESD protection is likely to result a PCB failure 3 1 Removal 1 Remove Rear cover Milf 3 3 1 2 Remove all connectors from the PCB B x8 3 Squeeze the barbs of the pins and remove PCB Replacement 1 Reinstall PCB 2 Reconnect all connectors to the PCB B EE x8 3 Make sure all DIP switches are set to OFF according to picture NOTE Make sure replaced PCB has matched software with the system refer ring to the latest Technical Bulletin 4 Reinstall Rear cover li 33 1 3 70 29 November 2006 PCB 3 7 3 LOWER MD6DC PCB C C P4 C P5 Uu C P11 C P13 C P3 Mee C P14 p ot d OW 6 5 lt X CAUTION ESD Hazard ESD Electrostatic Discharge can cause software crashes data and or communications problems Failure to use prop
44. x 24 4 65 kgs 144 Ibs 2 E O 70 25 sheets of 80 gsm 20 Ib Bond Same as Trimmer FTR 200 Up to 1800 sets hour 910 x 350 x 620 mm 35 8 x 13 8 x 24 4 52 kgs 115 Ibs Spec 1 Page intentionally blank 29 November 2006 WIRING Booklet Maker oee pocket at rear of manual for wiring diagrams Trimmer oee pocket at rear of manual for wiring diagrams Squarefolder oee pocket at rear of manual for wiring diagrams Wir 1 Page intentionally blank
45. 00 will be connected 5 Connect the powercord E to the Booklet maker x1 6 Mount the cable protector H positioned as shown with two screws in the holes I and route the cables inside the cable protector x 2 7 Attach the sticker Do not lift here J on the cable protector 8 Install the cable holders on the rear side of the Booklet Maker and route the cables through them A B G C F D E EN m Only Booklet Maker installed 1 J HERE PAS LEVER AE HF INFE 29 November 2006 TRIMMER INSTALLATION 1 4 TRIMMER INSTALLATION 1 4 1 ACCESSORY CHECK S 72 rm L Lj i T C E F Check the quantity and condition of the accessories in the box against the follow ing list NOTE The Installation Box is located in the trim bin on the Trimmer The trim bin is tie wrapped on the rear side Trimmer fan is bubble wrapped and located inside the Trimmer The Rail Extension is located in the packing material Description Q ty A Communication cable between the Booklet maker 1 and the Trimmer B Powercord between the Booklet maker and Trimmer 1 C Trimmer lan E EO 1 D Cable DIOIGCLIO 1 E Cable protector sticker 1 Gane qoo
46. 09 Fault Code BM 209 indicates that during a run the Outfeed sensor Booklet maker BM Q8 was not blocked within timeout Initial Actions Check fuse F2 on Transformer Make sure that the Outfeed sensor Booklet maker 8 is installed correctly Ensure that the Outfeed sensor Booklet maker 08 is clean Procedure Enter the Service mode and select Outfeed sensor Booklet maker 8 in check sensors Block then unblock the BM Q8 with a sheet of paper The Outfeed sensor Booklet maker BM Q8 sensor indicates 0 when the sensor is blocked and 1 when the sensor is not blocked Y N Go to BM 039 fault code Make sure that nothing interferes with the paper path BM 210 Fault Code BM 210 indicates that at initialization or during a run the Outfeed sensor Booklet maker BM Q8 was blocked exceeding timeout Initial Actions Check fuse F2 on Transformer og Make sure that the Outfeed sensor Booklet maker 8 is installed correctly 3 9 Ensure that the Outfeed sensor Booklet maker 08 is clean e Procedure Enter the Service mode and select Outfeed sensor Booklet maker BM Q8 in check sensors Block then unblock the BM Q8 with a sheet of paper The Outfeed sensor Booklet maker BM Q8 sensor indicates 0 when the sensor is blocked and 1 when the sensor is not blocked Y N Go to BM 039 fault code Make sure that nothing interferes with the paper path BM 401 Fault Co
47. 20 29 November 2006 TRIMMER INSTALLATION 2 5 A muU ea yd a r C E mu H F L HERE INTE PAS LEVER i3 RHET AJ FEIER Trimmer with cable protector installed Continued on next page 1 21 TRIMMER INSTALLATION 29 November 2006 Booklet Maker with Trimmer installed 1 E s Booklet Maker rear side 1 22 29 November 2006 SQUAREFOLDER INSTALLATION 1 5 SQUAREFOLDER INSTALLATION 1 5 1 ACCESSORY CHECK S 72 A B C D F G H 1 J K M Check the quantity and condition of the accessories in the box against the following list Description Q ty A Communication cable 1 D POW ESE CONG 1 C Auto set thickness bracket with Spring 1 D Sensor bracket with sensor 1 E Spacer pin and screw 2 25 mm washer and screw 2 Extended trim bin two parts 1 Screw ana TUE 4 Tapping cable 50MM 27 ba a uc ink nd 1 COM SQF 200 sticker
48. 3 Connect the sensor harness D to the sensor on bracket E x 1 1 34 29 November 2006 PM TABLE 2 PREVENTIVE MAINTENANCE SCHEDULE 2 1 PM TABLE NOTE Amounts mentioned as the PM interval indicate the number of sets Jt CAUTION If any of the checkpoints or other parts show indication of wear at any point replace the part When lubricating clean the surface if necessary before applying new lubricant o gt 06 c c o 9 us 6 symbol key C Clean R Replace L Lubricate I Inspect 375K 500K NOTE REFERENCE Bowrbus if 7 Section 33 Oil Every 20K 3 4 17 2x 3 4 16 Stapler heads 2x Inspect Replace if 3 4 12 needed Stapler Drive Bar Folder assembly Fold knife drive bars 2 Fold roller bearings x6 x2 bracket Cams to Upper fold L L L L Grease 3 6 11 Item J rollers 2x Drive Driving belt Fold Inspect Replace if 3 6 7 transmission needed Fold transmission Inspect Replace if coupling assy needed 2 1 PM TABLE 29 November 2006 125K 250K 375K 500K NOTE REFERENCE Paperpatns C C C Senses c C C C BlowerBush _ Infeed module Outfeed module Upper outfeed belts C C C Alcohol 3 2 15 2X Lower outfeed belts Alcohol 3 2 14 2X Trim Knife 1 inspect 328 Drive Knifechain L L L L J
49. ASE SOLENOID SOL2 y SN NOR HUM V LH Ms rb Continued on next page 3 46 29 November 2006 AREA B Removal 1 Start Staple Fold positioning motor M9 in Check motors 5 1 1 Engage the motor until you can see the screws A Remove Infeed cover fl 3 3 2 Cut the tie wrap securing the cable Disconnect connector to SOL2 x1 e W N Loosen screws x2 Adjustment 1 When the Stapled stop gate is in it s upper position the play in the solenoid plate B should be 0 1 0 5 mm If not go to step 2 2 Loosen screws A x2 prm ot 7 6 5 lt 3 Adjust according to step 1 4 Tighten screws A x2 Replacement 1 Reverse the removal procedure 3 47 AREA B 29 November 2006 3 9 3 SADDLE STAPLING START SENSOR Q4 A B Removal 1 Remove nut A amp x1 2 Disconnect connector B E x1 Replacement 1 Reverse the removal procedure NOTE Make sure that the sleeve of the wire do not interfere with the paper path 3 48 29 November 2006 AREA C 3 6 AREAC 3 6 1 STAPLE FOLD POSITION MOTOR M9 amp SENSOR Q10 T 2 gt 9 0 N 6 5 lt X A 1 Set machine to A4 8 5x11 2 Remove Outfeed cover 3 3 4 3 Disconnect connectors x2 4 Remove screws B to
50. BOOKLET MAKER BM 200 SERVICE MANUAL 29 November 2006 Subject to change Page intentionally blank IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY Always connect the equipmenttoa erly grounded power source In doubt have the power source checked by a qualified electrician WARNING Improper connection of the equipment grounding conductor can result in electrical shock Always follow all warnings marked on or supplied with the equipment Always locate the equipment on a solid support surface with adequate strength for the weight of the machine Always exercise care in moving or re locating the equipment Always keep magnets and all devices with strong magnetic field away from the chine Never use a ground adapter plugto con nect the equipment to a power source that lacks a ground connection terminal Never attempt any maintenance function that is not specifically described in this documentation Never remove the covers or guards that are fastened with screws unless you are a trained Service representative Never install the unit near a radiator or any other heat source Never override or cheat electrical or me chanical interlock devices Never operate the equipment if you notice unusual noises or odors Disconnect the power cord from the power source and call your customer service engineer to correct the problem 1 Before disassembling or assembling parts of the Bo
51. CRIPTIONS BM 045 Fault Code BM 045 indicates that the Fold Gap Sensor BM Q37 is faulty Initial Actions Make sure that the Fold Gap Sensor BM Q37 is installed correctly Procedure 1 Replace sensor BM Q37 2 Disconnect plug F P3 from Addon PCB Measure between J3 2 and J3 4 5V and ground The voltage is approximately 5 VDC Y N Replace Addon PCB Disconnect plug from sensor BM Q37 Check wire for Continuity Short circuit from the white wire Q37 to F P3 3 Is there Continuity and no Short circuit Y N Replace wire Harness Connect plug F P3 to Addon PCB Measure between the red wire Q37 and the black wire Q37 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness Replace Addon PCB BM 150 Fault Code BM 150 indicates that the 36V input is high Initial Actions o 50 22 Fr v Make sure that contact P8 on interlock PCB is correctly installed Make sure that contact P12 on controller PCB is correctly installed Make sure that the transformer in the machine is wired correcly Procedure Power on machine Measure incoming voltage on Rectifier White and Blue The voltage is approximately 26V Y N Replace transformer Measure outgoing voltage on rectifier Red and Black The voltage is approximately 36V Y N Replace Rectifier Power off the machine Measure between the black connector on the Rectifier and P6 3 on interlock PCB Is there continu ity
52. Cams to the upper folder rollers Replacement 1 Reverse the removal procedure NOTE Screws securing the bearings to the folder rollers on the rear side must be thightened with 10 Nm NOTE Make sure to lubricate with Molybdenum grease according to 3 6 10 3 64 29 November 2006 AREA C 3 6 12 LOWER FOLDER ROLLER A pa 5 OW 65 o lt c E F G Continued on next page 3 65 AREA C 29 November 2006 Removal 1 2 Remove outfeed cover Mii 3 3 4 Remove the paper guide A by pressing it against the rear side of the Booklet maker Remove Fold distance bracket 3 6 10 Remove nuts B and bearing brackets C on the front and rear side of the booklet maker x2 NOTE Use the Caster tool to remove the springs NOTE Bearings F X2 are pressed on to the axle journals from factory and can therefore not be removed Gently remove the Lower folder rollers Replacement 1 2 Reinstall the Lower folder rollers Reinstall the bearings F X2 on the rear side of the Booklet maker NOTE On the newer type of folder rollers the bearings are allready pressed on to the axle journals from factory NOTE Make sure to lubricate with Molybdenum grease according to 3 6 10 Reinstall springs E on the front and rear side of the Booklet maker 2 Insert the Caster tool with the pointed end in the h
53. EAR SENSORS Q2 AND SQF 3 16 3 3 3 CLAMP MOTOR HOME POSITON SENSOR Q4 SQF 3 17 3 3 4 INFEED OUTFEED SENSORS Q5 AND Q SQF 3 18 3 3 5 CLAMP SENSOR Q6 SQF 3 20 3 3 6 MOTOR M4 ENCODER SENSOR 8 SQF 3 21 3 3 7 TOP COVER INTERLOCK SWITCHES 52 amp 54 SQF 3 22 3 3 8 UPPER TRANSPORT BELT CLUTCHES SOL1 amp SOL3 SQF 3 23 3 3 9 LOWER TRANSPORT BELT CLUTCHES SOL2 amp SOL4 SQF 3 24 22 BELT e SQF 3 25 341 UPPER TRANSPORT BELT SQF 3 25 3 4 2 LOWER TRANSPORT BELL brew tuve teo SQF 3 26 3 4 3 TEFLON TAPE LOWER TRANSPORT BELT SQF 3 29 39 IME CHANICS E SQF 3 31 S SQF 3 31 3902 STOP GATE SQF 3 34 220 POB C P SQF 3 37 36t eusie eaoin SQF 3 37 POWER REQUIREMEN TS itr ope SQF 3 39 3 7 1 TAPPING THE TRANSFORMER SQF 3 39 TROUBLESHOOTING 4 1 FAULT CODE 5 2 SQF 4 1 42 BLOWN FUSE SQF 4 13 459 CED d SQF 4 15 44 sane cium SQF 4 17 5 SERVICE TABLES 5 1 SERVICE TABLES 6 DETAILED SECTION DESCRIPTION 6 1 ELECTRICAL COMPONENT LIST 6 1 1 CO
54. ICE PROGRAM MODE 5 1 5 1 2 SERVICE PROGRAM MODE 5 4 Check Motors and 5 4 5 1 3 EEPROM RESET 5 12 5 2 SOFTWARE DOWNLOAD asta sade 5 13 5 2 1 Downloading to upper PCB MD6DC B in Booklet maker 5 13 5 2 2 Downloading to lower PCB MD6DC in the Booklet maker 5 14 5 2 3 Downloading to PCB CPU Booklet maker 5 15 5 2 4 Downloading to lower PCB MD3DC H in the Booklet maker 0 16 5 2 5 Downloading to PCB MD6DC A in Trimmer 5 17 5 2 6 Downloading to MD6DC D in Squarefolder 5 18 5 3 SELF DIAGNOSTIC MODE 2 5 19 5 3 1 RUN TIME 5 5 19 532 FOVWER ON SELF TES T pda xk Ian Ka PER 5 19 5 3 3 DETAILED SELF DIAGNOSTIC 5 20 5 4 PAPER SIZE RESE T 5 21 Pet 5 25 DETAILED SECTION DESCRIPTIONS 6 1 ELECTRICAL COMPONENT LIS T rio ieu HIR RM REC a iR OR E 6 1 I FRONT VIEW 6 3 SM P NE REAR VIE 6 4 6 19 CONNECTOR VIE VV a Dot E es 6 5 OUTPFEED UPPER VIEW
55. LLATION 1 11 ACCESSORY Sate ites 1 11 142 INSTALLATION PISOGEDUISE n 1 12 152 ADJUSTMENTS 1 14 UR Eo DIOS EE 1 17 TAS Un UE 1 20 1 9 SOQUAREFOLDER INSTALLATION o 1 23 KI ACCESSORY CHECK lt tta dde 1 23 1 5 2 INSTALLATION PROCEDURE cibum 1 24 ADJUSTMENTS essct avena uM bci 1 27 DOG dio CM IE 1 30 TIo CONNECTFOR e EE 1 32 1 5 6 AUTO SET THICKNESS BRACKED 1 33 PREVENTIVE MAINTENANCE SCHEDULE PNEU US No I 2 1 REPLACEMENT AND ADJUSTMENT Sal GENERAELECAUTIONS bate dioc 3 1 3 2 SPECIAL TOOLS AND LUBRICANT S 3 3 oc OE CHG MO OLS custodias gale etos 3 3 S22 REQUIRED TOOLS 3 5 292 9 IMBOLSIUSEDIN TEX deals tings 3 5 SM COVER EE 3 7 FRONTAND REAR COVER m Uem 3 7 3 2 INFEED COVER DN 3 8 INEF eer ere er eee reer cr ee ere meer 3 9 Se COVER utat M uae uU cM UMS 3 10 UPPER TOP GOVER t bon qum eae 3 11 REAR TOP COVER ne Maiden iud Dant dudas 3 12 Dod JqOPOOVE
56. MPONENT LAYOUT 6 2 BOARD STRUCTURE 6 2 1 CONTROLLER MD6DC D 6 3 PRINCIPLE OF OPERATION SPECIFICATIONS SPECIFICATIONS WIRING Squarefolder XII SQF Spc 1 SQF Wir 1 29 November 2006 INSTALLATION REQUIREMENTS 1 INSTALLATION PROCEDURE 1 1 INSTALLATION REQUIREMENTS 1 1 1 MINIMUM SPACE REQUIREMENTS c O S o0 26 4 15 75 FTR 200 BM 200 625 mm 350 mm 350 mm LA 5 mm 24 38 13 75 13 75 31 9 2135 mm 84 21 9 1 1 INSTALLATION REQUIREMENTS 29 November 2006 1 1 2 POWER REQUIREMENTS WARNING Make sure that the wall outlet is near the main machine and easily accessible Make sure the plug is firmly inserted in the outlet Avoid multi wiring Be sure to ground the machine 1 Input voltage level North America 120 AC 50 60Hz More than 4 Europe Asia 230V AC 50 60Hz More than 2 A 2 Permissible voltage fluctuation 10 3 Never place anything on the power cord 29 November 2006 INSTALLATION FLOW CHART 1 2 INSTALLATION FLOW CHART The following flow chart shows how to install the optional units more efficiently S 72 Install the Booklet maker BM 200 Does the user require a Trimmer No Install the Trimmer FTR 200 Does the user require a SquareFolder Yes No Is a Trimmer installed Yes No Install Trimmer Install the SquareFolder SQF 200 Install the Belt Stacker Check the Installation
57. NOTE Check adjust Stapler pressure 3 9 4 Replacement 1 Reverse the removal procedure 3 88 29 November 2006 BOOKLET QUALITY ADJUSTMENT 3 9 7 STAPLE AND FOLD POSITION Purpose The purpose is to ensure that the set is folded in the center of the set and that the staple is positioned in the center of the set A ot oy 77 6 5 lt Shown in tipped position for clarity Initial Action 1 Check adjust Side Guide Parallelism 3 9 2 2 Make sure that the value Index 3 Rear jogger offset in EEPROM values is the same value as the value on the label in the back of the machine 3 If not Change the value in EEPROM values to the value on the label 4 Setup the Booklet maker for 297x420 mm 11 17 in Custom size NOTE Do NOT use the preset A3 or 11x17 paper sizes 5 Hand feed a 2 sheet set using 297x420 mm 11 17 paper 6 Runafew sets 7 Check that the staples are aligned with fold and that the fold is in the middle of the set If not go to Adjustment Continued on next page 3 89 BOOKLET QUALITY ADJUSTMENT 29 November 2006 Staple Adjustment ile 2 Check adjust Paper size reset 54 Set up the Booklet maker for 297x420 mm 11 17 in Custom size NOTE Do NOT use the preset A3 or 11x17 paper sizes Hand feed a 2 sheet set using 297x420 mm 11x17 paper Run a few sets Check that the staples are
58. NSERT TOOL will be shown 11 Insert the tool according to pictures below 12 Press OK E 9 N The sharp end of the tool on the other end of the tool by the 3rd 3rd stop finger back jogger finger 13 The text Adjust B Jogger will be shown 14 Turn the adjustment screw to move the back jogger fingers so the finger just touches the tool slightly Adjustment screw below infeed module 1 Correct No tension no play Qu 15 Press 2 The text REMOVE TOOL will be shown 16 Remove the tool Press OK The text IS TOOL REMOVED will be shown 17 Press OK 5 23 Page intentionally blank 29 November 2006 SQF SERVICE 5 5 SQF SERVICE In the Squarefolder Service menu you are able to set up the Squarefolder to Ad justment mode Use the Adjustment mode when adjusting the Square folding qua lity When the Adjustment mode is set to ON the Home position of the Stop gate is changed So you will be able to adjust the Stop gate during run Adjustment mode Set the Adjustment mode to ON when performing Stop gate adjustment A SOF 200 Service Manual 3 5 2 NOTE When you are done with the adjustment remember to set the Adjust ment mode to OFF 1 Enter the Service Program mode 2 Go to SQF 200 Service Press the OK button 3 Scroll to Adjust mode Press the CHG button so it says ON in the UI 4 Press the OK button 5 25 Page intentionally blank 29 Nove
59. OKLET MAKER INSTALLATION 1 3 3 ADJUSTMENTS 9 S 72 1 Remove screws A and remove the Booklet maker front cover x5 2 Remove screws B loosen screw C and remove the Bookler maker rear cover x5 BOOKLET MAKER INSTALLATION 29 November 2006 3 Mount the supplied positioning pins on the collator 4 Dock the collator to the Booklet maker See picture above 29 November 2006 BOOKLET MAKER INSTALLATION S 72 Booklet Maker front view A 5 Turn the four adjustment nuts A until the distance B between the lower edge of door and the top of side guide is 3 mm 6 Reinstall the Booklet maker front and rear covers x 10 BOOKLET MAKER INSTALLATION 29 November 2006 1 3 4 CONNECTORS 1 Ifa collator is present connect the communication cable A from the collator E x1 to the Booklet maker 2 Connect the Belt Stacker cable B x1 NOTE Unless Trimmer FTR 200 and or SquareFolder SQF 200 will be in stalled If so Belt Stacker cable will be connected to the last module in the system 3 Install the Terminator plug C and the Interlock jumper NOTE The Terminators and Interlock jumpers are stored in the installation kit 4 Install the Terminator plug D and the Interlock jumper F NOTE Unless Trimmer FTR 200 will be installed If so communication cable and power cord between BM 200 and FTR 2
60. Ol 3219 Kmfesupotchan L L L L On sate Chain sprockets Gearrack L L Grease 132100 320 25K NOTE REFERENCE All machine paper C C Blower brush path etc Transport belt C I R C I R Alcohol 3 4 1 amp 3 4 2 Pressure roller Inspect O rings and 3 2 4 pressure roller Change position of wear point of pressure roller Replace Com plete assy if needed Link Arms for Inspect Link Arms Clamps for wear Replace if needed Lower Clamp L L Check that the lower 3 5 1 Clamp moves when pressed by upper Clamp Grease Teflon Tape Inspect Replace if 3 4 3 needed Dampers Replace dampers 3 5 2 Adjust stop gage To prevent flatness of pressure roller 29 November 2006 GENERAL CAUTIONS 3 REPLACEMENT AND ADJUSTMENT 3 1 GENERAL CAUTIONS WARNING Turn off the main power switch and unplug the machine before attempting any of the procedures in this section Using the ESD Ground Strap Purpose The purpose of the ESD Electrostatic Discharge ground strap is to preserve the inherent reliability and quality of electronic components handled by the Service Representative The strap should be used whenever handling the circuit boards or any other ESD sensitive components gt ot oy 7 6 5 ELA o lt Procedure NOTE All procedures requiring use of the ESD ground strap will contain a caution referring to this
61. P5 1 on MD6DC C PCB Is there con tinuity Y N Replace wire harness Measure for continuity between P4 2 on MD6DC B PCB and P5 2 on MD6DC C PCB Is there continuity Y N Replace wire harness Replace MD6DC B PCB BM 160 Fault Code BM 160 indicates that the PCB MD6DC C is not connected Initial Actions sure that all connectors are properly connected to PCB MD6DC Make sure that the dipswitches on the PCB are set correctly 5 2 2 Procedure Power off the machine Measure for continuity between P4 1 on MDGDC PCB and P2 1 on Controller PCB Is there con tinuity Y N Replace wire harness Measure for continuity between P4 2 on MD6DC C PCB and P2 2 on Controller PCB Is there continuity Y N Replace wire harness Replace MD6DC B PCB BM 161 Fault Code BM 161 indicates that the PCB MD3DC H is not connected Initial Actions Make sure that all connectors are properly connected to PCB MD3DC H Make sure that the dipswitches on the PCB are set correctly 5 2 4 Procedure Power off the machine Measure for continuity between P4 1 on MD3DC H PCB and P5 1 on MD6DC B PCB Is there con tinuity Y N Replace wire harness Measure for continuity between P4 2 on MD6DC C PCB and P5 2 on MD6DC B PCB Is there continuity Y N Replace wire harness Replace MD6DC B PCB 4 26 29 November 2006 FAULT CODE DESCRIPTIONS BM 201 Fault Code BM 201 indicates that during a run the P
62. RASSEMDBICY ex le tt as mU 3 13 3 38 TINTERLOCOCK SWITGOEUS TO 49 f 3 15 p ARE AA 3 17 ST INEEBDNODULE MUS DEUM IMMER 3 17 OZ FAPERINFEED SENSOR SRI ania etie ttis 3 18 3 4 3 INEEED TRANSPORT MODULE 3 19 3 4 4 INFEED TRANSPORT MEER ERUIT 3 20 3 4 5 INFEED MOTOR M1 SENSOR 02 3 21 SAO JSIDBEOUIDES ssepe bn MU AIDE SR EU MU D PURI 3 22 3 4 7 SIDE JOGGER MOTOR amp SENSOR 2 3 23 3 4 8 SIDE GUIDE TRANSMISSION amp SENSOR Q193 3 24 3 4 9 BACK JOGGER MODULE 8 SENSOR 3 26 3 4 10 BACK JOGGER 3 28 3 4 11 BACK JOGGER MOTOR 2 3 30 3412 STAPLER HEAD aas E RI RENDUM nS 3 31 3 4 13 STAPLER HEAD RETRACTION 3 34 3 4 14 STAPLER MOTOR 3 35 3 4 15 STAPLER ASSY DRIVE amp SENSOR Q14 3 36 3 4 16 CLINCHER BAR ASSEMBLY eee 3 37 3 4 17 CLEANING CLINCHER 3 38 3 4 18 SET TRANSPORT DRIVE 3 39 3419 PRESSURE ROLLER uie dU IMPR qu EU 3 41 3 4 20 SET TRANSPORT MOTOR M5 eese 3 42 3421 THICK SET SENSOR REE 3 43 9 5 AREA Ducha UM Mist
63. TE The clincher points D are not interchangeable They must be refitted on their original position 4 Clean clincher bar A clincher plate C and clincher points D NOTE Check for wear replace if needed 5 Apply oil on moving surfaces Replacement 1 Reverse the removal procedure 2 Before refitting the clincher bar assembly check adjust the Clincher points height 3 9 5 3 38 29 November 2006 AREA A 3 4 18 SET TRANSPORT DRIVE ALIGNMENT D C B ot oy 77 6 5 lt D E Continued on next page 3 39 AREA A 29 November 2006 Purpose The purpose is to horizontally align the Set transport drive rollers with the Idler wheels to ensure the correct set transportation into the fold area 1 2 9 Set the machine to A4 8 5x11 Ensure that the tires A are centered on the hubs B of the drive rollers Manually move the Drive rollers C up against the Pressure rollers D by pushing the Staple stop gate down Visually check that the Drive rollers C are centered on the Pressure rollers D Removal 1 Remove Infeed cover I 3 3 2 Adjustment 1 Oo 22 dw Insert a 0 3 mm feeler gauge E to ensure 0 3 0 2 mm endplay If not go to step 2 NOTE The endplay 0 3 mm is to prevent the Staple stop gate shaft from binding Loosen allen screw F amp x 1 Push the shaft G toward the Front of the Booklet m
64. The xCAN portion on MD6DC is not used in the Booklet maker as the external communication is handled by the xCAN portion on the CPU PCB In the Trimmer and the Squarefolder the xCAN portion on MD6DC is used for ex ternal communication as 6 15 BOARD STRUCTURE 29 November 2006 6 2 3 CONTROLLER MD6DC CONTINUES BM M1 BM M8 9 ST M1 BM M6 BM M4 BM M2 BM SOL1 BM M3 BM SOL2 Booklet maker Set counter BM M5 6 16 29 November 2006 6 2 4 CONTROLLER MD3DC MD3DC CANO StariExi CAN1 IVes MA Bi directional motors Lower current Motor dr lt O W Debug i UARTO Flash download UART1 MCU SOLA Sol d Sensors Inputs x8 52 SOLB 9 SOLC Counter Ri i Motor sensors x4 4 pole DIP Motors Voltage AID feedback UNREG The MD3DC PCEB is present in Booklet maker x1 as 6 17 29 November 2006 6 2 4 CONTROLLER MD3DC CONTINUES BM M19 29 November 2006 BOOKLET MAKING PROCESS 63 BOOKLET MAKING PROCESS 6 3 1 PRINCIPLE OF OPERATION M1 Q4 M3 Compiling Collator sends a start signal The pre infeed motor BM M19 and infeed motor BM M1 start The set enters the infeed module Infeed sensor BM Q1 activates oide guides moves half way in BM M3 The infeed wheel transports the set down to the staple stop The set stops at the stap
65. ULE 2 1 PREVENTIVE MAINTENANCE SCHEDULE FTR 2 1 3 REPLACEMENT AND ADJUSTMENT 9 1 COVERS FTR 3 1 3 1 1 FRONT AND REAR esses FTR 3 1 3252 POR COVER ima tin Padi FIR 3 2 3 9 BLOWER MOTOR MS FMO FTR 3 3 SkA INF REED COVER FTR 3 4 LOCKING BRACKET FTR 3 5 XEO UPPER OUTFEED GOV ER FTR 3 6 3 1 7 INTERLOCK SWITCH 9 amp 510 FIR 3 7 Sc EOWERAOUTIEEED COVER FTR 3 8 3 1 0 PROTEC TON COVER erareto FTR 3 9 22 FTR 3 11 32 JNEEED SENSOR QT sci FTR 3 11 32 2 CONTROL SVWITGOFI S2 amar FTR 3 12 32 0 CONTROL SWICK SOS erisin nn FTR 3 13 32 4 TRANSPORT MOTOR M1 suissterosiveinerivenitioiedbesatenbwinaveklaedie FTR 3 14 3 2 5 TRANSPORT BELT SENSOR 04 FIR 3 15 3 26 TRIMIANIFE MOTOR M2 FIR 3 16 3 2 7 TRIM KNIFE HOME POSTITON SENSOR Q25 FIR 3 17 3 20 TRIMKNIF a FTR 3 18 3 2 9 PAPER PATH amp OUTFEED SENSOR Q6 FTR 3 22 3 2 10 gt GATE CARRIAGE FTR 3 23 3 2 11 STOP GATE MOTOR amp SENSOR
66. Voltage supplies BM M19 Pre Infeed motor MD6DC B 29 43V Unregulated 36V after interlock relay distributed from Interlock PCB in Booklet maker Voltage supplies BM M1 Infeed motor BM M7 Fold knife motor 8 Fold stop gate motor BM M9 Staple fold pos mot ST M10 Stacker motor MD6DC C 29 43V Unregulated 36V after interlock relay distributed from Interlock PCB in Booklet maker Voltage supplies BM M2 Back jogger motor BM M3 Side jogger motor BM M4 Stapler motor BM M5 Set transport motor BM M6 Fold roller motor Ground only to BM SOL1 Stop gate sol BM SOL2 Stop gate rel sol BM Set counter FTR 200 29 43V Unregulated 36V after interlock relay distributed from Interlock PCB in Booklet maker Voltage supplies FTR M1 Transport knife motor FTR M2 Knife motor FTR M3 Stop gate motor FIR MA Length adjust motor FTR Set counter Ground only to FTR M5 Blower motor FTR M6 Blower motor SQF 200 29 43V Unregulated 36V after interlock relay distributed from Interlock PCB in Booklet maker Voltage supplies SQF M1 Transport belt motor SQF M2 Stop Gate motor SQF M3 Clamp motor SQF M4 Roller motor 5 1 Belt stacker motor SQF Set counter 5 9 SERVICE PROGRAM MODE 29 November 2006 Values BEEN Dem password to enter service mode can be changed here STD Trim 004 50 Standard trim margin that is default pre sented in the user menu Value reflects how many millimetres that will be tr
67. Y N Go to BM 034 fault code Make sure that nothing interferes with the paper path BM 203 Fault Code BM 203 indicates that during a run the Start sensor Saddle stapling BM Q4 was not blocked within timeout Initial Actions Check fuse F2 on Transformer Make sure that the Start sensor Saddle stapling BM Q4 is installed correctly Ensure that the Start sensor Saddle stapling BM Q4 is clean Procedure Enter the Service mode and select Start sensor Saddle stapling BM Q4 in check sensors Block then unblock the BM Q4 with a sheet of paper The Start sensor Saddle stapling BM Q4 sensor indicates 0 when the sensor is blocked and 1 when the sensor is not blocked Y N Go to BM 035 fault code Make sure that nothing interferes with the paper path 4 27 FAULT CODE DESCRIPTIONS 29 November 2006 BM 204 Fault Code BM 204 indicates that at initialization or during a run the Start sensor Saddle stapling BM Q4 was blocked exceeding timeout Initial Actions Check fuse F2 on Transformer Make sure that the Start sensor Saddle stapling BM Q4 is installed correctly Ensure that the Start sensor Saddle stapling BM Q4 is clean Procedure Enter the Service mode and select Start sensor Saddle stapling BM Q4 in check sensors Block then unblock the BM Q4 with a sheet of paper The Start sensor Saddle stapling BM Q4 sensor indicates 0 when the sensor is blocked and 1 when the sensor is not
68. aker Adjust distance according to step 1 Tighten allen screw F amp x 1 Loosen allen screws H E x2 Move the assembly so that the tires A are centered the Pressure roll ers D Tighten allen screws H x2 Replacement 1 Reverse the removal procedure 3 40 29 November 2006 AREA A 3 4 19 PRESSURE ROLLER Replacement Adjustment Purpose The purpose is to position the Pressure rollers for the correct engagement with the Drive rollers This adjustment interacts with 3 5 1 Adjustment 1 the machine to 11x17 2 Check that the distance A is 24 5 mm NOTE Use a sliding caliper to measure the distance from paper path to the top of the pressure rollers Make sure not to push down the rollers as the measurement in that case will not be correct Adjust Press roller height A on the two nuts B x2 NOTE If you want to make the Distance A grater turn the two nuts B CW If you want to make the Distance A smaller turn the two nuts B CCW Make sure that the distance from the paper path to the top of the paper guides C is 7 10 mm If paper guides C is deformed form paper guides to obtain adjustment Check Adjust the Staple Stop Gate Solenoid 3 5 1 3 41 AREA A 29 November 2006 3 4 20 SET TRANSPORT MOTOR M5 p Ju B A C Remove Infeed cover 33 21 Remove screw A to ground strap x1 Re
69. al Reading ST M1 15V 2 or Stacker Motor transports the set on the belt 29V 2 stacker 5 5 SERVICE PROGRAM MODE 29 November 2006 Check Solenoids and function Booklet Maker BM SOL1 Will be actuated Stop Gate Solenoid moves the staple stop down for appr 30 sec and the set transport rollers up down BM SOL2 Will be actuated Stop Gate Release Solenoid releases the staple for appr 5 sec stop when latched in down position Squarefolder SQF SOL1 Will be actuated Belt drive engagement solenoid until sensor SQF SQF SOL2 Q6 is actuated SQF SOL3 Will be actuated until sensor SQF SQF SOL4 Q6 is actuated 5 6 29 November 2006 SERVICE PROGRAM MODE Check Sensors Switches and function Booklet Maker Senor Normal State Function Trimmer Sensor Normal State FTR S2 S3 O Unactuated Switch Control Switch Infeed Control Switch Out feed FIR Q5 1 Blocked Trim Knife Home Position Sensor FTR Q6 1 Unblocked Outfeed Sensor 5 7 SERVICE PROGRAM MODE 29 November 2006 Squarefolder Sensor NormalState Function NOTE SQF Q2 and SQF Q3 are home position sensors for the Roller motor one is blocked the other must be unblocked and vice versa 5 8 29 November 2006 SERVICE PROGRAM MODE Voltmeter MD3DC H 29 43V Unregulated 36V after interlock relay distributed from Interlock PCB in Booklet maker
70. an 26V Y N Replace the interlock PCB Go to 36V output low Fault code description BM153 Go to 36V input high Fault code description BM150 Measure between P4 1 and P4 2 on the interlock PCB The voltage is more than 43V Y N The voltage is less than 26V Y N Replace the interlock PCB Go to 36V output low Fault code description BM153 Replace the interlock PCB 4 22 29 November 2006 FAULT CODE DESCRIPTIONS BM 153 Fault Code BM 153 indicates that the 36V output is low Initial Actions Make sure that all the connectors properly installed on the interlock Procedure Power on machine and close covers Measure between P6 1 and P6 3 on the interlock PCB The voltage is approximate ly 36V Y N The voltage is less than26V Y N The voltage is more than 43V Y N Replace the interlock PCB Go to 36V output high Fault code description BM150 Go to 36V input low Fault code description BM151 Measure between P4 1 and P4 2 on the interlock PCB The voltage is less than 26V Y N The voltage is more than 43V Y N Replace the interlock PCB Go to 36V output high Fault code description BM152 Replace the interlock PCB o 50 8 8 Fr v BM 154 Fault Code BM 154 indicates that the 24V output is high Initial Actions Make sure that all the connectors are properly installed on the BM 200 interlock Enter Service mode run Trimmer motors M5 6 make sure that they run corre
71. and washer amp x1 x1 6 Remove the Crank wheel G 7 Remove screws to the motor x3 Replacement 1 Reinstall screws H to the motor x3 NOTE DO NOT TIGHTEN THE SCREWS Reinstall the Crank wheel G Reinstall screw and washer F amp x1 x x1 Tighten screws x3 xw N Reinstall Crank journal E with an 17 mm open wrench NOTE Make sure to install the grater end of the Crank journal 6 Reverse the rest of the removal procedure 3 35 AREA A 29 November 2006 3 4 15 STAPLER ASSY DRIVE BAR amp SENSOR Q14 DEEST NN NME MAL 0 05 to 0 15 mm 0 0 B M Bl o A e is 5 D lt C D Purpose The purpose is to limit the front to rear movement of the Stapler assembly drive bars without causing them to bind Removal 1 Remove Front and Rear cover 3 3 1 2 Remove Infeed cover 3 3 2 Adjustment 1 Push the Drive bar A toward the Rear of the Booklet maker 2 Insert a feeler gauge to Check the gap B The distance should be 0 05 0 15 mm If not go to step 3 Loosen locknuts amp x2 Adjust screws D according to step 2 X2 Tighten locknuts C amp x2 Qu Perform the same check on the Rear side E adjust if needed Replacement 1 Reverse the removal proc
72. aper infeed sensor BM Q1 was not blocked within timeout after the start signal from the collator was detected Initial Actions Check fuse F2 on Transformer Make sure that the Paper infeed sensor BM Q1 is installed correctly Ensure that the Paper infeed sensor BM Q1 is clean Procedure Enter the Service mode and select Paper infeed sensor BM Q1 in check sensors Block then unblock the BM Q1 with a sheet of paper The Paper infeed sensor BM Q1 sensor indicates 0 when the sensor is blocked and 1 when the sensor is not blocked Y N Go to BM 034 fault code 1 Make sure that nothing interferes with the paper coming out from the collator and going in to the Booklet maker 2 Make sure that nothing interferes with the paper path in the Booklet maker 3 Make sure that the Booklet maker is correctly installed BM 202 Fault Code BM 202 indicates that at initialization or during a run the Paper infeed sensor BM Q1 was blocked exceeding timeout Initial Actions Check fuse F2 on Transformer Make sure that the Paper infeed sensor BM Q1 is installed correctly Ensure that the Paper infeed sensor BM Q1 is clean o 50 22 Fr v Procedure Enter the Service mode and select Paper infeed sensor BM Q1 in check sensors Block then unblock the BM Q1 with a sheet of paper The Paper infeed sensor BM Q1 sensor indicates 0 when the sensor is blocked and 1 when the sensor is not blocked
73. approximately 36 VDC Y N Replace PCB Replace wire Harness Replace motor BM M2 BM 007 Fault Code BM 007 indicates that the Side jogger motor BM M3 does not receive any displacement pulses Initial Actions Check fuse F2 on Transformer Enter the Service mode and select Side jogger motor BM M3 check motors o 20 Fr v Procedure Disconnect the sensor plug Q12 to motor BM M3 Measure between the red wire Q12 and the black wire Q12 5V and Signal ground The voltage is approximately 5 VDC Y N Disconnect plug C P14 from PCB Measure between the J14 6 and J14 8 5V and Signal ground The voltage is approximately 5 VDC Y N Replace PCB Replace wire harness Disconnect plug C P14 from PCB Check wires for Continuity Short circuit from the gray wire 012 to C P14 4 the white wire Q12 to C P14 7 the black wire Q12 to C P14 6 the red wire Q12 to C P14 8 Is there Continuity and no Short circuit Y N Replace wire harness 1 Replace motor BM M3 2 Replace PCB 4 5 FAULT CODE DESCRIPTIONS 29 November 2006 BM 008 Fault Code BM 0068 indicates that the Side jogger motor BM M3 had a Cycle time out Initial Actions Check fuse F2 on Transformer Enter the Service mode and select Side jogger motor BM M3 in check motors Make sure that the Side jogger home position sensor 1 3 is installed correctly Procedure Enter the S
74. are located to high Ro tate the allen screw counterclockwise if the clincher points are located to low 5 Repeat the above procedure until theclincher points are flush with the upper side of the clincher bar Replacement 1 Reverse the removal procedure 3 86 29 November 2006 BOOKLET QUALITY ADJUSTMENT 3 9 6 CLINCHER PRESSURE A B pa o E d OW 6 5 lt X A 4 U 9 p Continued on next page 3 87 BOOKLET QUALITY ADJUSTMENT 29 November 2006 Purpose The purpose is to achieve the correct flat form of the staples Removal Front 1 2 3 4 Check adjust Clincher points height 3 9 5 Remove Infeed cover 3 3 2 Remove Stapler heads 3 4 12 Rotate the motor linkage see Removal step 4 3 9 4 to the down dead center Adjustment 1 ES uu a 5 Insert the Multi Tool A so lever B becomes pressed down Loosen the nut C until the bushing D can just barely be rotated by hand 69 1 Tighten nut 2 revolutions more 1 Repeat the procedure on the Rear side of the Booklet maker Check adjust Stapler pressure 3 9 4 Reinstall Stapler heads 3 4 12 Run a set of 22 sheets 80 gsm Check that the staples are flat If not go to step 8 Tighten the nut A 74 revolutions more j x1 Check adjustment according to step 5
75. as a Outfeed cover removed BM MO9 BM Q7 8 BM Q10 ELECTRICAL COMPONENT LIST 29 November 2006 6 1 6 INFEED UPPER VIEW BM M1 BM Q2 BM Q1 Inffeder removed 6 8 29 November 2006 ELECTRICAL COMPONENT LIST 6 1 7 INFEED LOWER VIEW BM SOL2 BM M5 BM SOL1 BM Q14 vo 9 26 25 as a BM Q15 BM M4 BM M7 6 9 ELECTRICAL COMPONENT LIST 29 November 2006 6 1 8 INFEED MODULE VIEW Bottom view BM M3 BM Q13 BM Q3 BM M2 BM Q12 29 November 2006 ELECTRICAL COMPONENT LIST 6 1 9 STACKER MODULE VIEW T M1 vo 25 Qo a 6 11 Page intentionally blank 29 November 2006 62 BOARD STRUCTURE 6 2 1 BLOCK DIAGRAM BOARD STRUCTURE Bookfold Trimmer Bookletmaker o 29 Addon MD3DC electrical MD6DC signals MD6DC Collator Comm Optocouplers gt Collator Ul gt Interlock A Interlock Lead The electronics in the BM 200 is distributed and divided in four different PCBs one CPU board CPU PCB PL76 and three motor drive boards two PCB MD6DC and one MD3DC Each PCB has their own processor they are communicating via internal CAN iCAN The system also has many support PCBs such as one interlock PCB and one collator interface PCB The CPU
76. bly when tightening the screws 7 Retrieve a new job then retrieve the job you where working with 8 Goto step 1 3 91 BOOKLET QUALITY ADJUSTMENT 29 November 2006 3 9 9 STAPLE POSITION ON SQUARE FORMED SPINE Purpose The purpose is to position the staples on the square formed spine according to customer preferences Factory default is within the spine A Shown in tipped position for clarity MN 7 Adjustment NOTE This adjustment will affect all types of booklets If the staple position is adjusted on a 20 sheet booklet with Square formed spine a big difference will be seen Staple position will then be miss aligned also on a 2 sheet booklet but the difference will not be as notice able 1 Disconnect the Trimmer from the Booklet maker 2 Loosen lock nut A on the fold pocket amp x1 3 Adjust by turning allen screw x1 Turn allen screw CW if the staples are on the top edge C of the spine Turn allen screw CCW if the staples are on the lower side D of the spine 4 Tighten lock nut A on the fold pocket 1 29 November 2006 POWER REQUIREMENTS 3 10 POWER REQUIREMENTS 3 10 1 TAPPING THE TRANSFORMER A d OW 6 5 lt X B Purpose Transformer in picture tapped for 230 To be able to change the Transformer setting Removal 1 Remove screw A and renove Transformer cover amp x1 2 Rem
77. board is equipped with a 32 bit ARM processor which has two CAN as channels iCAN and xCAN iCAN to communicate with the motor drive boards and XCAN to communicate with other external units such as the Trimmer The power supply to the Trimmer is taken from the Booklet Maker The Booklet Maker also controls the interlock system An interlock lead connects the interlock PCB and the Trimmer The interlock lead goes through a cover switch on the Booklet Maker and Trimmer 6 13 BOARD STRUCTURE 29 November 2006 6 2 2 CONTROLLER CPU e CAN2 LPC2292 GPIO AD 4 y interlock Start Exit ARM CPU Expansion 1 16 KB 256 KB Atmega48 128KB Expansion 2 Flash download UARTO Support 2 8 UART1 CPU isi Expansion Staplers 7 hall SPI Ch 1 Addon Ul Collator Expansion SPICh2 interface 6 14 29 November 2006 BOARD STRUCTURE 6 2 3 CONTROLLER MD6DC MD6DC CANO Start Exit MA Bi directional motors D MB Lower current MD Bi directional motor ME Higher current UARTO One directional motor Higher current Sol d Inputs x8 6 2 SOLB Notin use Spo DU Voltage feedback UNREG The MD6DC is present in Booklet maker x2 Trimmer x1 and Squarefolder x1
78. cording to step 9 in Removal section Replacement 1 Reverse the removal procedure 3 80 29 November 2006 BOOKLET QUALITY ADJUSTMENT 3 9 2 SIDE GUIDE PARALLELISM ot oy 77 6 5 lt Stapler area seen from above with the stapler heads removed Removal Front 1 Check adjust Staple stop gate parallelism 3 9 1 2 Remove Infeed cover ap 33 2 3 Remove screw and B to the Front side guide P x2 NOTE The nut plate may fall down into the machine 4 Same procedure on the Rear side guide D Adjustment 1 Mowve the side guide C to the two holes E and F in the paper path 2 Check the distance between the two holes and the side guide The distance should be equal 0 3 mm between the lower hole E and the side guide C and the upper hole F and the side guide C If not go to step 3 Loosen screw A also loosen screw B a little Adjust the side guide C ac cording to step 2 P x2 Perform the same check on the Rear side guide D adjust if needed Replacement 1 Reverse the removal procedure 3 81 BOOKLET QUALITY ADJUSTMENT 29 November 2006 3 9 3 STAPLE POSITION TO CLINCHER CAUTION Alignment of the stapler head to clincher is carried out at factory Screws are sealed with red paint to ensure that alignment is maintained and also to indicate if it has been moved Alignment will not change over ti
79. ctly Procedure Power on machine and close covers Measure between J14 11 and J14 8 and between J12 11 and J12 8 on the interlock PCB The voltage is approximately 24V at both measurements Y N Measure between J6 1 and J6 3 on the interlock PCB The voltage is approximately 36V Y N The voltage is more than 43V Y N The voltage is less than 26V Y N Replace the interlock PCB Go to 36 V input low Fault code description BM151 Go to 36 V input high Fault code description BM150 Replace the interlock PCB Replace the interlock PCB 4 23 FAULT CODE DESCRIPTIONS 29 November 2006 BM 155 Fault Code BM 155 indicates that the 24V output is low Initial Actions Make sure that all the connectors are properly installed on the BM 200 interlock PCB Enter Service mode and run Trimmer motors M5 6 make sure that they run correctly Procedure Power on machine and close covers Measure between J14 11 and J14 8 on the interlock PCB The voltage is approxi mately 24V Y N Measure between J6 1 and J6 3 on the interlock PCB The voltage is approximately 36V Y N The voltage is more than 43V Y N The voltage is less than 26V Y N Replace the interlock PCB Go to 36 V input low Fault code description BM151 Go to 36 V input high Fault code description BM150 Replace the interlock PCB Replace the interlock PCB BM 156 Fault Code BM 156 indicates that one of the interlock switches in the system is faulty Initial Actions Ch
80. de BM 401 indicates that the stapler head is faulty Initial Actions Check stapler head 3 4 12 Procedure Disconnect the connectors to the stapler heads Disconnect plug A P1 from CPU PCB Check wire for Continuity Short circuit from the rear stapler head lead to the A P 1 24 and the front stapler head lead to the A P1 15 Is there Continuity and no Short circuit Y N Replace wire Harness Replace CPU PCB 4 29 FAULT CODE DESCRIPTIONS 29 November 2006 ST 001 Fault Code ST 001 indicates that the Stacker motor ST M1 has a Short circuit Initial Actions Make sure that the connectors are properly installed on the stacker motor Procedure Disconnect the motor plug M1 Run the Diagnostics again Fault code ST 002 Open circuit is displayed Y N Disconnect plug P2 from PCB B Check wires for Short circuit across leads the red wire M1 to P2 11 violet and the black wire M1 to P2 4 orange Is there Short circuit Y N Replace PCB Replace wire Harness Replace motor ST M1 ST 002 Fault Code ST 002 indicates that the Stacker motor ST M1 has an Open circuit Initial Actions Make sure that the connectors are properly installed on the stacker motor Procedure Disconnect the motor plug M1 Enter Service mode and start Stacker motor ST M1 in check motors Measure between the red wire M1 and the black wire M1 24V and ground The voltage is approximately 24 VDC Y N Disconnect plug P2 f
81. e 1 Replace sensor BM Q1 2 Disconnect plug A P1 from CPU PCB Measure between J1 7 and J1 9 5V and ground The voltage is approximately 5 VDC Y N Replace CPU PCB Disconnect plug from sensor BM Q1 Check wire for Continuity Short circuit from the white wire Q1 to A P1 8 Is there Con tinuity and no Short circuit Y N Replace wire Harness Connect plug A P1 to CPU PCB Measure between the red wire Q1 and the black wire Q1 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness Replace CPU PCB 4 17 FAULT CODE DESCRIPTIONS 29 November 2006 BM 035 Fault Code BM 035 indicates that the Start sensor Saddle stapling sensor BM Q4 is faulty Initial Actions Make sure that the Start sensor Saddle stapling sensor BM Q4 is installed correctly Procedure 1 Replace sensor BM Q4 2 Disconnect plug A P1 from CPU PCB Measure between J1 4 and J1 6 5V and ground The voltage is approximately 5 VDC Y N Replace CPU PCB Disconnect plug from sensor BM Q4 Check wire for Continuity Short circuit from the white wire Q4 to A P1 5 Is there Con tinuity and no Short circuit Y N Replace wire Harness Connect plug A P1 to CPU PCB Measure between the red wire Q4 and the black wire Q4 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness Replace CPU PCB BM 038 Fault Code BM 038 indicates that the Fold stop sensor 7 is faulty Initia
82. e BM 200 6 3 3 1 3 Run the BM 200 CPU 1 00 file v1 00 is an example use latest version and follow the instruction in the program or according to the latest bulletin 4 When the download is complete set the contrast of the LCD by turning the potentiometer 41 4 4 5 Perform a EEPROM RESET 5 1 3 6 Either perform a Paper Size Reset 5 4 or use the values previously noted in step 5 R41 5 15 SERVICE PROGRAM MODE 29 November 2006 5 2 4 Downloading to lower PCB MD3DC H in the Booklet maker CAUTION ESD Hazard ESD Electrostatic Discharge can cause software crashes data and or communications problems Failure to use proper ESD pro cedures will cause damage to electronic components example PCBs ESD problems can be minimized by maintaining all machine ground con nections ensuring the proper handling of circuit boards and sensors Use ESD protection when working near PCBs Failure to use ESD protection is likely to result in a PCB failure 3 1 1 Switch Off the Main Power Switch 2 Remove Rear Cover 2 2 1 3 Make sure DIP switches 2 is set to ON down position Make sure DIP switches 1 3 and 4 is set to OFF up position 4 BM 200 MD3DC v1 00 exe file v1 00 is an example use latest version and follow the instruction in the program or according to the latest bulletin NOTE A red LED on the board will flash while downloadin
83. e Q2 5V and Signal ground The voltage is approximately 5 VDC Y N Disconnect plug B P14 from PCB B Measure between the J14 13 and J14 15 5V and Signal ground The voltage is approximately 5 VDC Y N Replace PCB B Replace wire harness Disconnect plug B P14 from PCB Check wires for Continuity Short circuit from the white wire Q2 to B P14 14 the black wire Q2 to B P14 13 the red wire Q2 to B P14 15 Is there Continuity and no Short circuit Y N Replace wire harness 1 Replace motor BM M1 2 Replace PCB BM 002 Fault Code BM 002 indicates that the Infeed motor BM M1 has a Short circuit Initial Actions Check fuse F2 Transformer o 50 22 Fr v Procedure Disconnect the motor plug M1 Run the Diagnostics again Fault code BM 003 Open circuit is displayed Y N Disconnect plug B P2 from PCB Check wires for Short circuit across leads the orange wire M1 to B P2 8 violet and the violet wire M1 to B P2 1 orange Is there a Short circuit Y N Replace PCB B Replace wire Harness Replace motor 1 BM 003 Fault Code BM 003 indicates that the Infeed motor BM M1 has an Open circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M1 Enter Service mode and start Infeed motor BM M1 in check motors Measure between the orange wire M1 and the violet wire M1 PWM 36V and ground The voltage is approximately
84. e wire Harness Replace motor 19 BM 042 Fault Code BM 042 indicates that the Pre Infeed Motor BM M19 has an Open circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M19 Enter Service mode and start Pre Infeed Motor BM M19 in check motors Measure between the orange wire M19 and the violet wire M19 PWM 36V and ground The voltage is approximately 36 VDC Y N Disconnect plug H P2 from PCB H Start Pre Infeed Motor BM M19 in check motors again Measure between J2 1 and J2 8 PWM 36V and ground The voltage is approximately 36 VDC Y N Replace PCB H Replace wire Harness Replace motor BM M19 BM 044 Fault Code BM 044 indicates that the Thick Set Sensor BM Q36 is faulty Initial Actions Make sure that the Thick Set Sensor BM Q36 is installed correctly Procedure 1 Replace sensor BM Q36 2 Disconnect plug F P2 from Addon PCB Measure between J2 1 and J2 4 5V and ground The voltage is approximately 5 VDC Y N Replace Addon PCB Disconnect plug from sensor BM Q36 Check wire for Continuity Short circuit from the white wire Q36 to F P2 3 Is there Continuity and no Short circuit Y N Replace wire Harness Connect plug F P2 to Addon PCB Measure between the red wire Q36 and the black wire Q36 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness Replace Addon PCB 4 20 29 November 2006 FAULT CODE DES
85. each the screw through the hole in the Infeed module 3 Remove connector B x1 3 18 29 November 2006 3 4 3 x amp x s F a NUM ZI tu 4 4 d uA ap l s i ae g if z i ES A Remove connectors A x2 Cut tie wrap Remove C C x1 AREA A INFEED TRANSPORT MODULE B pa 5 OW 65 5 lt c Remove pin to the Infeed transport module AREA A 29 November 2006 3 4 4 INFEED TRANSPORT WHEEL B 1 Remove Infeed transport module 3 4 3 2 Remove nuts A x3 3 Remove E clip B x1 3 20 29 November 2006 AREA A 3 4 5 INFEED MOTOR M1 amp SENSOR Q2 pa 5 OW 65 5 o lt c A Remove Infeed transport wheel 5 4 4 Remove screws x3 Pull out the Infeed motor M1 amp sensor Q2 NOTE The sensor Q2 is located on the motor 3 21 AREA A 29 November 2006 3 4 6 SIDE GUIDES D C A B Removal Front 1 Remove Infeed module 3 4 1 2 Remove screw A and B to the Front side guide C 2 3 Same procedure on the Rear side guide D Replacement 1 Reverse the removal procedure NOTE Make sure that you are using the correct screws M4 x 8mm when reinstalling
86. ear end of the stapler head until the release lever snaps into place locking the stapler head in position Press down the front end of the stapler head until it snaps in position under the frame assembly Reconnect the staple indication lead D Close the top cover and switch on the booklet maker The booklet maker will automatically cycle and advance staples until both staple heads are driving staples If an error message occors repeat procedure 3 33 AREA A 29 November 2006 3 4 13 STAPLER HEAD RETRACTION DISTANCE Purpose The purpose is to ensure the staple feed Removal 1 Remove Infeed cover g 3 3 2 2 Make sure that the Stapler motor linkage is in the top dead center Adjustment 1 Push down the stapler head A Check that the gap B is 1 0 2 0 mm If not go to step 3 Loosen screws x3 Adjust screws D according to step 2 x1 Tighten screws C oS Perform the same check on the Rear side E adjust if needed Replacement 1 Reverse the removal procedure 3 34 29 November 2006 AREA A 3 4 14 STAPLER MOTOR M4 H A F B C D o E d OW 6 5 lt X E Removal 1 Remove Infeed cover li 3 3 2 2 Disconnect connector A Eg x1 3 Remove nut B brass spacer C and screw D amp x1 amp x1 4 Remove Crank journal E with an 17 mm open wrench 5 Remove screw
87. eck that the Transformer is tapped to the correct voltage 3 10 1 Ifatrimmer is not installed make sure that the interlock jumper Parts Catalog page 8 Item 7 is installed in the BM 200 If a trimmer is installed make sure that the interlock jumper Parts Catalog page 8 Item 7 is installed in the FTR 200 Make sure that all the connectors to the interlock switches are properly installed Procedure Use interlock cheaters to close all covers Measure between P1 1 and P1 2 on the BM 200 Interlock PCB Is there continu ity Y N Replace the BM 200 interlock switch Measure between 1 4 and 1 5 on the BM 200 interlock Is there an open circuit Y N Replace the BM 200 interlock switch Measure between 1 1 and P1 2 on the 200 interlock Is there continuity Y N Replace the FTR 200 interlock switch Measure between P1 4 and P1 5 on the FTR 200 interlock Is there an open circuit Y N Replace the FTR 200 interlock switch eplace the interlock PCB 4 24 29 November 2006 FAULT CODE DESCRIPTIONS BM 157 Fault Code BM 157 indicates that the 36V output relay is faulty Initial Actions Check fuse F2 Procedure Power on machine Measure between P6 1 and P6 3 on the Interlock PCB The voltage is approximately 36VDC Y N The voltage is less than 26VDC Y N The voltage is more than 43V Y N Replace Interlock PCB Go to 36V input high Fault code description BM150 Go to 36V input low Fau
88. ed Press OK 4 Press Arrow two arrows appear if motor is bi directional to start the motor symbol appears if motor is off Press Cycle button motors with defined positions only to let the motor perform one working cycle NOTE Motors with defined positions also shows status H 1 or H 0 of corresponding sensor 5 Press Stop to stop the motor symbol appears if motor is running Press ESC to exit that motor check which leaves it running NOTE When checking 9 you have to press the cycle button before being able to press the Arrow buttons To get the position of the motor NOTE For safety reasons you have to press the unlock button to be able to start FTR M2 You have to press the unlock button between every cycle Checking Sensors All sensors can individually be checked by blocking unblocking sensors While blocking unblocking view the display for response Displayed is the state by 1 or 0 Which state corresponding to blocked unblocked is depending on whether the sensor has inverted function or not For status definition see Service Program Mode Tables 5 1 2 Running Dead Cycling free run Dead cycling is a modified machine cycle All functions in the machine are run such as motors and solenoids The program is basically made for factory testing but can be of some use when trouble shooting 1 Remove the two stapler heads 2 Go to Dead Cycling Press OK 3 Press Arrow to go to the unit in which t
89. edure 3 36 29 November 2006 AREA A B PES Pd Pid NN NON VW SOM 3 NON NON n Mo 5 T P SC NN n 2 x 27 5 Soe Nos 4 Pid x Incorrect with gap ww ot 7 6 5 o lt c Correct no gap Removal 1 Setthe machine to A3 11x17 2 Remove Infeed module a 3 4 1 3 Remove screws and nuts A on both sides of the Booklet maker x2 9 x2 4 Remove the screws B fastening the clincher beam on both sides of the Booklet maker x2 5 Lift out the Clincher bar assembly Replacement 1 Reinstall the Clincher bar assembly NOTE Make sure that the spring C is positioned on top of the Stapler assy drive bar 2 Before tightening the screws B make sure that the Clincher bar assembly is firmly seated D NOTE There should be no space D If you look at the clincher bar through the positioning holes in the Front and Rear frame 3 While pressing the Clincher bar assembly tighten the screws B X2 4 Reverse the rest of the removal procedure 3 37 AREA A 29 November 2006 3 4 17 CLEANING CLINCHER POINTS Removal 1 Remove Clincher bar assembly A eig 3 4 16 2 Remove screws to clincher plate C x3 3 Remove clincher plate C NO
90. eed side On the SQF 200 1 Make sure that the belt stacker is in its normal operating position Press down on the lever A that prevents opening the cover B of the belt stacker Hold the Cheater above the with the interlock with the arrow pointing upwards 2 3 4 Putin the left end in the slot so it hooks under the bracket 5 Push the Cheater down and to the right so it latches in place A 29 November 2006 3 2 2 REQUIRED TOOLS Open wrenches 5 5 7 8 10 13 17 19 mm Allen keys 1 5 2 2 5 3 4 5 mm Torx T 20 Circlip pliers Metric Feeler gauge set Metric Sliding calliper 3 2 3 SYMBOLS USED IN TEXT Go to section Screw 2 Allen screw E clip amp Usea Screwdriver N 3 5 SPECIAL TOOLS AND LUBRICANTS ot oy 77 6 5 o lt 4 Nut A Connector EEJ Washer Page intentionally blank 29 November 2006 COVERS 3 3 COVERS 3 3 1 FRONT AND REAR COVER 5 os On 65 lt X A B C Open top cover Remove screws to Front cover x5 Remove screws B to Rear cover x4 gt N Loosen screw x1 NOTE Unhook the Rear cover 3 7 COVERS 29 November 2006 3 3 2 INFEED COVER B Remove Front and Rear cover gi 3 3 1 Remove screws amp 2 Support Infeed Cover Remove screws B to remove Infeed Cover OTE Remove screws in this order
91. er ESD pro cedures will cause damage to electronic components example PCBs ESD problems can be minimized by maintaining all machine ground con nections ensuring the proper handling of circuit boards and sensors Use ESD protection when working near PCBs Failure to use ESD protection is likely to result in PCB failure 4 3 1 Removal 1 Remove Rear cover Mii 3 3 1 2 Remove all connectors from the PCB C x8 3 Squeeze the barbs of the pins and remove PCB C Replacement Reinstall PCB C 2 Reconnect all connectors to the PCB C E x8 3 Make sure DIP switches 1 and 4 is set to ON according to picture NOTE Make sure replaced PCB has matched software with the system refer ring to the latest Technical Bulletin 4 Reinstall Rear cover 3 3 1 3 71 PCB 29 November 2006 3 7 4 INTERLOCK PCB D D P5 D P6 D P8 A D P9 D P13 D P10 D P11 A CAUTION ESD Hazard ESD Electrostatic Discharge can cause software crashes data and or communications problems Failure to use proper ESD pro cedures will cause damage to electronic components example PCBs ESD problems can be minimized by maintaining all machine ground con nections ensuring the proper handling of circuit boards and sensors Use ESD protection when working near PCBs Failure to use ESD protection is likely to result a PCB failure 3 1 1 Remove Rear cover ug 3 3 1 2 Re
92. ervice mode and select Side jogger home position sensor BM Q13 in check sensors The Side jogger home position sensor indicates 1 when the sensor is blocked and 0 when the sensor is unblocked Y N 1 Replace sensor BM Q13 2 Disconnect plug C P13 from PCB Measure between J13 4 and J13 6 5V and ground The voltage is approximately 5 VDC Y N Replace PCB Disconnect plug from sensor BM Q13 Check wire for Continuity Short circuit from the white wire Q13 to C P13 5 Is there Continuity and no Short circuit Y N Replace wire Harness Connect plug C P13 to PCB C Measure between the red wire Q13 and the black wire Q13 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness Replace PCB Is the two outer back jogger fingers in it s right position 3 4 9 Position the two outer back jogger fingers in their correct position 3 4 9 1 Lubricate were needed 2 Replace motor BM M3 BM 009 Fault Code 009 indicates that the Side jogger motor BM M3 has a Short circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M3 Run the Diagnostics again Fault code BM 010 Open circuit is displayed Y N Disconnect plug C P2 from PCB Check wires for Short circuit across leads the orange wire to C P2 9 violet and the violet wire M3 to C P2 2 orange Is there Short circuit YN Replace PCB
93. example PCBs ESD problems can be minimized by maintaining all machine ground con nections ensuring the proper handling of circuit boards and sensors Use ESD protection when working near PCBs Failure to use ESD protection is likely to result PCB failure 3 1 1 Switch Off the Main Power Switch 2 Remove rear cover 3 3 1 Run the SQF 200 MD6DC v1 00 exe file v1 00 is an example use latest ver sion and follow the instruction in the program or according to the latest bulletin NOTE The DIP switches must be in the off position 5 18 29 November 2006 SELF DIAGNOSTIC MODE 5 3 SELF DIAGNOSTIC MODE 5 3 1 RUN TIME DIAGNOSTICS Throughout the operation of the machine all functions and components are moni tored Should an error occur a fault code is displayed Many faults can simply be corrected by the operator In that case a picture shows the location of the fault with a text message such as Clear Misfeed s If the fault can not be corrected by the operator the text message Fault in area is displayed All messages regardless of nature are always accompanied by a fault code The operator manual lists the fault codes that the operator can solve This manual lists all fault codes To correct the fault go to Fault Code Descriptions 4 1 5 3 2 POWER ON SELF TEST At power on the program checks the EEPROM It checks that it is present and not corrupt If not present or corrupt the mac
94. from PCB C Check wires for Short circuit across leads the orange wire M4 to C P3 7 violet and the violet wire M4 to C P3 6 orange Is there Short circuit Y N Replace PCB Replace wire Harness Replace motor BM M4 BM 013 Fault Code BM 013 indicates that the Stapler motor BM M4 has a Open circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M4 Enter Service mode and start Stapler motor BM M4 in check motors Measure between the orange wire M4 and the violet wire M4 PWM 36V and ground The voltage is approximately 24 VDC Y N Disconnect plug C P3 from PCB Measure between J3 6 and J3 7 PWM 36V and ground The voltage is approximately 24 VDC Y N Replace PCB o 5 Fr v Replace wire Harness Replace motor BM M4 BM 014 Fault Code BM 014 indicates that the Set transport motor BM M5 has a Short circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M5 Run the Diagnostics again Fault code BM 015 Open circuit is displayed Y N Disconnect plug C P2 from PCB C Check wires for Short circuit across leads the orange wire M5 to C P2 10 violet and the violet wire M5 to P2 3 orange Is there Short circuit Y N Replace PCB Replace wire Harness Replace motor BM M5 4 9 FAULT CODE DESCRIPTIONS 29 November 2006 BM 015 Fault Code BM 015 indicates
95. g When download is complete LED goes out oas A MR ITANE uu teme ot M n Th Mee Tuc EXC A pu 52 Us pe I MEM 4 umi 4 m 1 pans i 5 16 29 November 2006 SERVICE PROGRAM MODE 5 2 5 Downloading to PCB MD6DC A in Trimmer A CAUTION ESD Hazard ESD Electrostatic Discharge can cause software crashes data and or communications problems Failure to use proper ESD pro cedures will cause damage to electronic components example PCBs ESD problems can be minimized by maintaining all machine ground con nections ensuring the proper handling of circuit boards and sensors Use ESD protection when working near PCBs Failure to use ESD protection is likely to result a PCB failure 3 1 owitch Off the Main Power Switch Remove Rear Cover FTR 200 Service Manual 1 1 1 Make sure all DIP switches 1 4 is set to OFF down position Run the 200 MD6DC v1 00 exe file v1 00 is an example use latest version and follow the instruction in the program or according to the latest bulletin YS 5 17 SERVICE PROGRAM MODE 29 November 2006 5 2 6 Downloading to PCB MD6DC D in Squarefolder AN CAUTION ESD Hazard ESD Electrostatic Discharge can cause software crashes data and or communications problems Failure to use proper ESD pro cedures will cause damage to electronic components
96. g to en sure set is straightened up before folding BM M9 269mm 460mm Staple Fold Position Motor adjusts the position of the staple stop fold stop and back jogger for different paper sizes BM M19 14V x2V 0 4m s Pre Infeed Motor transports the set to the sta pling section 29 November 2006 SERVICE PROGRAM MODE Trimmer 22V 2V 0 7 0m s Transport Knife Motor transports the booklet in and out 0 70m s of the Trimmer unit It also functions as a second Trim Knife Motor when reversed In Service mode only transport direc tion can be run FTR M2 20V 2V Trim Knife Motor cycles knife to cut the book let FTR M3 28V 2V Stop Gate Motor moves the stop gate up to stop the booklet to be trimmed and down when transporting it out FTR M4 21V 2V Length Adjustment Motor adjusts the position of 120 220mm the stop gate for different booklet sizes FTR M5 Blower Motor blows the trimmed shingle cut M6 paper edge down to the scrap bin Squarefolder Motor Normal Reading SQF M1 17 5V x2V E Belt motor transports the bookletin B and out of the Squarefolder SQF M2 A Stop gate motor moves the stop gate up and down to stop the booklet in correct position SQF M3 N A Clamp motor opens and closes the Set clamp holding the booklet in place when the Roller motor are performing the book folding action SQF M4 12V 2V Roller motor performs the book folding action 0 35 m s Stacker Motor Norm
97. he corresponding function should be reset to zero That is done under EEPROM Values Jam History The last 40 error messages are listed here The most resent error at the top This is a very helpful tool when troubleshooting as all events are logged consecutive Displayed are the total count for the event and the fault code It is also logged when the service program mode has been entered It is indicated by a wrench symbol in front of the total count To remedy errors listed go to Fault Code Descriptions eg 4 1 5 3 SERVICE PROGRAM MODE 29 November 2006 9 1 2 SERVICE PROGRAM MODE TABLES Check Motors and function Booklet Maker 1 14V 2V x0 90m s Infeed Motor transports the set to the stapling section BM M2 9V 2V Back Jogger Motor jogs the sheets together lengthwise BM M3 200mm 325mm Side Jogger Motor adjusts the position of the side guides for different paper sizes It also jogs the sheets together sidewise and guides the set through the machine BM M4 15V 2V Stapler Motor drives the staples into the set and drives the clinchers that clinches the staple legs flat BM M5 24V 2V Set Transport Motor transports the set from the stapling area to the folding area BM M6 18V 2 0 25m s Fold Roller Motor folds and compresses the set and transport it out of the Booklet Maker BM M7 19V 2V Fold Knife Motor pushes the set up through the fold rollers BM M8 12V 2V Fold Stop Gate Motor makes a slight jo
98. he flashing indicates that a program is present and functioning Should a download fail or the 5V is missing LED would be OFF D2 Yellow LED flashes whenever information is sent or received on the Internal CAN If power is switched on but no operations are performed LED is OFF D26 Red LED lights to indicate that power to sensors is present 4 34 29 November 2006 LEDS CPU PCB in Booklet Maker D5 Ll luc o UU ou calo eo EL NM S 5 S ces J6 RNI R16 aliel zli 9 RN elas 1 D S eo ala E 9 229 82 nu 1 19 D 85 oj JOA tea ees era O o 92 ora TTia era E 2 8 8 LI E jfa i3 or x er 5 j x oj xf 13
99. he same amount of force throughout the turn Are you able to turn the motor without using a lot of force Y N Are the two outer back joggers finger in their right position 3 4 9 Item H Y N Position the two outer back jogger fingers in their correct position 3 4 9 1 Lubricate were needed 2 Replace motor BM M2 Replace motor BM M2 BM 005 Fault Code BM 005 indicates that the Back jogger motor BM M2 has a Short circuit Initial Actions e Check fuse F2 on Transformer Procedure Disconnect the motor plug M2 Run the Diagnostics again Fault code BM 006 Open circuit is displayed Y N Disconnect plug C P2 from PCB Check wires for Short circuit across leads the orange wire M2 to C P2 8 violet and the violet wire M2 to C P2 1 orange Is there Short circuit Y N Replace PCB Replace wire Harness Replace motor BM M2 29 November 2006 FAULT CODE DESCRIPTIONS BM 006 Fault Code BM 006 indicates that the Back jogger motor BM M2 has an Open circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M2 Enter Service mode and start Back jogger motor BM M2 in check motors Measure between the orange wire M2 and the violet wire M2 PWM 36V and ground The voltage is approximately 36 VDC Y N Disconnect plug C P2 from PCB C Start Back jogger motor BM M2 in check motors again Measure between J2 1 and J2 8 PWM 36V and ground The voltage is
100. he value reflects the time that you can out be logged in to service mode without touching any buttons before the machine closes the service mode 21 B 209 4 x H 296 5 2 B 296 4 x H 418 5 23 B 215 2 x H 279 2 B 215 2 x H 354 6 B 279 2 x H 431 0 B 256 3 x H 363 0 27 uos 0 2 ES EN 5 11 SERVICE PROGRAM MODE 29 November 2006 5 1 3 EEPROM RESET If minor logic problems arise the EEPROM reset procedure can be initiated All data in the EEPROM will be cleared including jobs jam history etc The only data not cleared are Counters Staple Fold Trim knife 1 Access the service menu and note the following EEPROM values Index 1 2 3 16 and 20 to 26 2 Make sure the main power to the Booklet maker is switched off 3 Press and hold the leftmost and rightmost button on the Control Panel 4 Switch ON the main power switch 5 Release the buttons on the Control Panel when the text CLEAR ING EEPROM is shown on the LCD This will be followed by text DONE on the LCD Key in the password press the OK button Press the ESC button Switch off the main power to the Booklet maker Or Sem Switch on the main power switch Default EEPROM values are restored Followed by this procedure it is advised to perform the Paper Size Reset in order to also reset the paper size parameters that have a great importance in the operation of the machine 5 4 Followed
101. hine will lock up If present and not corrupt the machine will enter normal operation mode unless A The service mode is entered B EEPROM reset is entered Power on Operation Service mode Machine mode 5 1 1 ar 3 lock up 5 19 SELF DIAGNOSTIC MODE 29 November 2006 9 3 3 DETAILED SELF DIAGNOSTIC MODE The main self diagnostic mode Diagnostics is available from the service program mode Diagnostics checks the EEPROM the sensors and the motors If a fault is found it will be displayed as a fault code To remedy the fault go to Fault Code Description ug 4 1 IMPORTANT Reflecting paper path sensors can be faulty although not detected by the diagnostics If they have a failure state equal to constantly unblocked it will not be detected as it is the correct home position state Should this failure occur it will be detected by the run time diagnostics Executing Diagnostics Follow this procedure to execute the diagnostics 1 Oo Undock the BM 200 2 Enter the service program mode 5 1 1 3 Remove the two stapler heads 3 4 12 4 5 Close the top cover If a Cover Feeder is installed make sure the adjustable side guides are in their innermost position Go to Diagnostics Press OK Press Run If a fault code is displayed go to Fault Code Descriptions 4 1 Locate the fault code and follow the procedure When the fault has been remedied go th
102. ide of the SquareFolder 1 29 SQUAREFOLDER INSTALLATION 29 November 2006 1 5 4 DOCKING Docking procedure B a 4 4 fim SquareFolder interior view towards Belt Stacker C 1 Loosen nuts A to the Locking bracket B 2 Dockthe SquareFolder to the Trimmer 3 Secure the SquareFolder by lifting the Locking bracket B and tightening nuts A 2 NOTE Make sure that the SquareFolder locking bracket B locks in the outer slot C on the positioning pin D 4 Install the new Extended trim bin 1 30 29 November 2006 SQUAREFOLDER INSTALLATION Installing Belt stacker 9 S 72 SquareFolder 1 Loosen screws x 2 on the SquareFolder 2 Install the Belt stacker on to the SquareFolder 3 Secure the Belt stacker by tightening screws A x 2 on the SquareFolder 1 31 SQUAREFOLDER INSTALLATION 29 November 2006 1 5 5 CONNECTORS A D E G Trimmer with SquareFolder installed 1 Move the Belt stacker cable A to the SquareFolder E x 1 NOTE Do not connect the Belt stacker cable A to the Trimmer 2 Move the Terminator plug B from the Trimmer to the SquareFolder x 1 3 Install the COM SQF 200 sticker C from the installation kit over the Termi nator sticker on the Trimmer 4 Install the Communication cable D between the Trimmer and the Square Folder x 1 5 Mount the cab
103. ighten allen screw B amp x1 NOTE Make sure that allen screw B is positioned against the D surface Reverse the rest of the removal procedure 3 52 29 November 2006 AREA C 3 6 4 FOLD STOP GATE o E d OW 6 5 lt X A B Removal 1 Set the machine to 11x17 2 Loosen locknut A amp x1 3 Remove screw B amp x1 4 Remove the Fold stop gate Replacement 1 Reinstall the Fold stop gate NOTE Make sure that the shaft on the Fold stop gate is positioned in the linkage 2 Reverse the rest of the removal procedure 3 53 AREA C 29 November 2006 3 6 5 FOLD KNIFE MOTOR M7 amp SENSOR Q15 D B 1 a ee a A E G J F Continued on next page 3 54 29 November 2006 AREA C Removal 1 EO ec A Cc N gt Remove sensor Q15 E Set the machine to 4 8 5x11 Remove Front and Rear cover 3 3 1 Remove Infeed cover 3 3 2 Disconnect connector A to motor M7 x1 Disconnect connector B to sensor Q15 EE x1 Loosen allen screw C and remove the stop ring amp x1 Remove screws D on front side of the Booklet maker x2 Remove the same screws on the rear side of the Booklet maker P x2 Remove the Fold knife motor M7 module S E ot oy 7 6 5 ELA o lt
104. immed off from the longest sheet centre fold in the booklet Side Jog Offset 4321 mm Reference regarding position for paper size adjustment Value reflects paper size width at home position Rear Offset 2 0mm_ Reference regarding position for paper size adjustment Value reflects paper size length at home position The counter for the stapler Value reflects the count of how much the stapler heads have cycled The counter for the folder Value reflects the count of how much the fold knife has cycled The counter for the trimmer Value reflects the count of how much the trimmer knife has cycled Staple Trim knife TI O Q Z m Squarefolder BM M1 Speed 01000 Low M1 Speed High 01400 1 BM M19 Speed 01900 LOW BM M19 Speed 02700 High BM M6 Speed 401900 The counter for the Squarefolder Value reflects the count of how many Books the Squarefolder has delivered The values reflect calibration of Infeed motor BM M1 Pre Infeed motor BM M19 and Fold roller motor BM M6 at power on NES I OO NO NO 14 gt NA NA 3 0 Zero Trim Offset Fine tuning of trim margin Value reflects deviation from real trim margin and STD trim margin 5 10 29 November 2006 SERVICE PROGRAM MODE EEPROM Values 17 FTR M1 Speed 01800 The value reflect calibration of Transport motor M1 Service Time T
105. in the middle of the set 7 of the input paper size 210 8 5 If the staple position is incorrect fine adjust by changing Index3 Rear jogger offset in EEPROM values Fold Adjustment 1 2 p gu m 0 Staple Adjustment must be performed before performing the Fold Adjustment Loosen screws A and rotate screws B to adjust the staples to the fold 2 F x2 NOTE Rotate both screws B same amount of turns clockwise if the sta ples are located on the bottom side of the set Rotate both screws B same amount of turns counterclockwise if the staples are located on the top side of the set Tighten screws Hand feed a 2 sheet set using 297x420 mm 11x17 paper Run a few sets Check that the staples are aligned with fold If not go to step 2 d 3 90 29 November 2006 BOOKLET QUALITY ADJUSTMENT 3 9 8 FOLD SKEW A 85 B 8 Shown in tipped position for clarity Purpose The purpose is to ensure that the fold is parallel to the edge of the sets Adjustment Hand feed a 2 sheet set using A3 11x17 paper Run a few sets Check that the fold is parallel to the edge of the set If not go to step 4 2 3 4 Loosen screws X2 5 Rotate the two screws B to adjust the fold pocket x2 NOTE Adjust according to the picture B B or or OY amp 9 J3 U 6 Tighten screws A P x2 NOTE Push in the fold stop assem
106. ion 1 Remove Side jogger motor 3 4 7 2 Loosen nuts B x2 c S Q 84 Use a screwdriver C to press the springs D together to slack the drive belt Remove screwdriver C 1 Remove connector A EZ x1 Remove Side jogger home position sensor Q13 E Use a flat plier to lift up the drive belt from the side guide brackets F SO Ib SO OF uem Remove the pulley G and the dive belt H Replacement 1 Place the side guides in there outermost position I 2 Take the pulley and press the drive belt into the left side guide bracket Continue and press the drive belt into the right side guide bracket F 3 Loosen nuts B and let the springs D tensioning the drive belt 2 4 Tighten nuts B again amp x2 5 Reverse the rest of the removal procedure 3 25 AREA A 29 November 2006 3 4 9 BACK JOGGER MODULE amp SENSOR Q3 D B A F G E C C Continued on next page 3 26 29 November 2006 AREA A Removal Sensor Q3 1 Remove Infeed cover 332 NOTE Picture shows Infeed module removed for clarity It is not necessary to remove Infeed module to replace Sensor Q3 2 Disconnect connector A to Sensor x1 3 Remove sensor Q3 B Replacement Sensor Q3 1 Reverse the removal procedure ot oy 77 6 5 lt
107. ircuit Y N Replace PCB Replace wire Harness Replace motor BM M7 4 12 29 November 2006 FAULT CODE DESCRIPTIONS BM 021 Fault Code BM 021 indicates that the Fold knife motor BM M7 has an Open circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M7 Enter Service mode and start Fold knife motor BM M7 in check motors Meas ure between the orange wire M7 and the violet wire M7 PWM 36V and ground The voltage is approximately 19 VDC Y N Disconnect plug B P3 from PCB Measure between J3 6 and J3 7 PWM 36V and ground The voltage is approximately 19 VDC Y N Replace PCB Replace wire Harness Replace motor BM M7 BM 022 Fault Code BM 022 indicates that the Fold stop gate motor 8 has a Short circuit Initial Actions 1 O 5 Check fuse F2 on Transformer 2 50 Procedure Fr v Disconnect the motor plug M8 Run the Diagnostics again Fault code BM 023 Open circuit is displayed Y N Disconnect plug B P2 from PCB B Check wires for Short circuit across leads the orange wire M8 to B P2 9 violet and the violet wire M8 to B P2 2 orange Is there Short circuit Y N Replace PCB Replace wire Harness Replace motor BM M8 BM 023 Fault Code BM 023 indicates that the Fold stop gate motor BM M8 has an Open circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the mot
108. is selected listing the peripherals Entering and Exiting the SP mode There are two ways to enter the service mode either from the operator mode or directly from switched off machine 1 Press the Tools button NOTE Insert interlock cheater if UNREG voltage for mo tors is needed 2 With the Arrow key select Service access and press the OK button 3 Key in password 1974 using the Arrow and Change button Press the OK button Exit 5 Switch off the main power to exit the Service mode or press the ESC button to exit the Service mode and enter the op erator mode p 1 Make sure the main power is switched off NOTE Insert interlock cheater if Uu NREG voltage for mo tors is needed 2 Press and hold the left hand button on the Control Panel 3 Switch on the main power switch 4 Release the button on the Control Panel NOTE When entering the SP mode this way the ma chine will reset the password to the default value 107 5 Key in password 1974 using the Arrow and Change button 6 Press the OK button Exit 7 Switch off the main power to exit the Service mode or press the ESC button to exit the Service mode and enter the op erator mode 5 1 SERVICE PROGRAM MODE 29 November 2006 Checking Motors and Solenoids 1 Go to Check Motors or Check Solenoids Press OK 2 Go to the unit in which the motor solenoid to be checked is located Press OK Go to the motor solenoid to be check
109. isconnect plug from sensor BM Q14 Check wire for Continuity Short circuit from the white wire Q14 to C P13 8 Is there Continuity and no Short circuit Y N Replace wire Harness Connect plug C P13 to PCB C Measure between the red wire Q14 and the black wire Q14 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness Replace PCB Is the crank journal correctly mounted agp 3 4 14 Item Y N Mount the crank journal correctly 3 4 14 Item 1 Remove the stapler heads 3 4 12 Does the stapler heads run as they should Y N 1 Make sure that there is no jammed staples in the stapler head 2 Lubricate the stapler head 3 Replace stapler head Move the right and left Clinch arm up and down Do they run as they should Ee 3 9 5 Y N 1 Remove any jammed staples 2 Lubricate the Clinch Remove the link arms to the crank journal Move the Lower stapler bracket by hand up and down Does it run as it should Y N 1 Make sure that nothing interferes with the movement 2 Adjust the stapler assy drive bar ap 3 4 15 Replace motor BM M4 29 November 2006 FAULT CODE DESCRIPTIONS BM 012 Fault Code BM 012 indicates that the Stapler motor BM M4 has a Short circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M4 Run the Diagnostics again Fault code BM 013 Open circuit is displayed Y N Disconnect plug C P3
110. l Actions Make sure that the Fold stop sensor BM Q7 is installed correctly Procedure 1 Replace sensor BM Q7 2 Disconnect plug A P1 from CPU PCB Measure between J1 10 and J1 12 5V and ground The voltage is approximately 5 VDC Y N Replace CPU PCB Disconnect plug from sensor BM Q7 Check wire for Continuity Short circuit from the white wire Q7 to A P1 11 Is there Continuity and no Short circuit Y N Replace wire Harness Connect plug A P1 to CPU PCB Measure between the red wire Q7 and the black wire Q7 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness Replace CPU PCB 4 18 29 November 2006 FAULT CODE DESCRIPTIONS BM 039 Fault Code BM 039 indicates that the Outfeed sensor Booklet maker BM Q39 is faulty Initial Actions Make sure that the Outfeed sensor Booklet maker 8 is installed correctly Procedure 1 Replace sensor BM Q8 2 Disconnect plug A P1 from CPU PCB Measure between J1 17 and J1 19 5V and ground The voltage is approximately 5 VDC Y N Replace CPU PCB Disconnect plug from sensor BM Q8 Check wire for Continuity Short circuit from the white wire Q8 to A P1 18 Is there Continuity and no Short circuit Y N Replace wire Harness Connect plug A P1 to CPU PCB Measure between the red wire Q8 and the black wire Q8 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness Replace PCB 2 040
111. le protector E positioned as shown with two screws in the holes and route the cables inside the cable protector x 2 6 Attach the sticker Do not lift here G on the cable protector 7 Install the cable holder on the rear side of the SquareFolder 8 Route cables through the cable holders on the rear side of the Booklet Maker Trimmer and SquareFolder 1 32 29 November 2006 SQUAREFOLDER INSTALLATION 1 5 6 AUTO SET THICKNESS BRACKET Auto set thickness bracket S 72 B ORAE A i C Booklet Maker rear side view 1 Remove the rear cover on the Booklet maker 1 3 3 P x5 2 Install the Spacer A with the collar out NOTE Install the Spacer pin s on the rear side of the Booklet maker 3 Install the Auto set thickness bracket B and tighten it with the other opacer pin C with the collar in CAUTION ONLY install spacer pin A and C finger tight Over tightening may break loose the screw from the Fold roller plate 1 33 SQUAREFOLDER INSTALLATION 29 November 2006 Sensor bracket A Booklet Maker rear side view E c B Booklet Maker rear side view Booklet Maker rear side view 1 Place the spring A on the screw on the Sensor bracket 2 Secure the Sensor bracket by tightening it with the screws B amp C P x2 torx NOTE Make sure that the Actuator runs in the sensor slot
112. le stop The start sensor BM Q4 by the staple stop activates The infeed wheel keeps on running for a period of time set by the paper size after the trail edge of the last sheet has passed the infeed sensor BM Q1 Detailed De scription BOOKLET MAKING PROCESS 29 November 2006 Q1 M2 M3 amp Q12 Q14 M4 Jogging and Stapling When start sensor BM Q4 is activated and infeed sensor BM Q1 deactivated back jogger motor BM M2 moves the back jogger up to knock the trail edge of the set At the same time the side jogger motor BM M3 moves the side guides against the paper plus a few millimeters to over jog the set by about 5mm depend ing on the set stiffness The side guides then moves outwards to the paper width plus about one millimetre The position is set by the paper width that has been en tered and found by encoder BM Q12 on side jogger motor At the same time the stapler motor BM M4 cycles putting staples through the center of the set When the staples contact the clinchers a closed circuit is established BM Q19 Q20 see page 6 21 by current running from stapler head through staple contacting the clincher The closed circuit created indicates that staples are present If out of staples the paper will insulate the stapler head from the clincher which will result in an open circuit The open circuit at this time will indicate out of staples The sta pler motor BM M4 will complete its cycle a
113. lt code description BM151 Measure between J5 1 and J5 2 The voltage is approximately 36VDC Y N The voltage is less than 26VDC Y N The voltage is more than 43V Y N Replace Interlock PCB Go to 36V output high Fault code description BM152 Go to 36V output low Fault code description BM153 o 50 8 8 Fr v Replace Interlock PCB BM 158 Fault Code BM 158 indicates that there is a communication lost problem Initial Actions Make sure that the communication cable between the BM 200 and the FTR 200 is properly connected Make sure that the communication cable between the 200 and the CF5010 is properly connected Procedure Power off the machine Remove all connectors to the FTR 200 Power on the machine Is there still communication lost Y N Replace the communication cable between the BM 200 and the FTR 200 Power off the machine Remove all connectors to the CF5010 Power on the machine Is there still communication lost Y N Replace the communication cable between the BM 200 and the CF5010 Replace the Interlock PCB 4 25 FAULT CODE DESCRIPTIONS 29 November 2006 BM 159 Fault Code BM 159 indicates that the PCB MD6DC B is not connected Initial Actions Make sure that all connectors are properly connected to PCB MD6DC B Make sure that the dipswitches on the are set correctly 5 2 1 Procedure Power off the machine Measure for continuity between P4 1 on MD6DC B PCB and
114. mber 2006 ELECTRICAL COMPONENT LIST 6 DETAILED SECTION DESCRIPTIONS 651 ELECTRICAL COMPONENT LIST Page Grid code BM M1 infeed MOto erc RU 6 8 2 2 Back Jogger MOLON 6 10 D2 SIGE jogger Motor a 6 10 s F2 BM M4 StaplerqnolOLbu sigo e ici Dire sia 6 9 H20 BM M5 SEL transport molor aci oc dios Seri CHO cients tal rd ao OS D a 6 9 E20 BM M6 Fold roller Motor tecta 6 3 H20 BM M7 Fold MOTON 5 EDI HIS UMEN MEINE EIL 6 3 6 9 E13 8 Fold stop gate 6 7 E16 BM M9 Staple Fold positioning motor 6 7 C19 BM M19 Pre Infeed 4440444608 6 4 G7 ST M1 Stacker moloF s eite bas m i d eate ei T 6 11 A20 BM Q1 Paper Infeed 6 8 H2 BM Q2 Infeed motor sensor located on motor M1 6 8 E2 BM Q3 Back jogger home position 6 10 G2 BM Q4 Saddle stapling start 6 6 N2 BM Q7 Fold 6 7 D16 BM Q8 Outfeed SensoE teeta 6 6 6 7 N2 BM Q9 Fold
115. me and will therefore not need further adjust ment However if the adjustment has been tampered with i e if red seal is broken it is very important to strictly follow the described procedure below The align ment of the stapler head to anvil is crucial and will determine the staple result as well as the lifetime of the stapler head The procedure requires 2 brand new stapler heads If at any time during the procedure the new stapler heads were cycled when adjustment were off staple legs not hitting the slot in the anvil clincher stapler heads are ruined and must be replaced The Stapler heads must be adjusted very precisely in order to achieve proper staple result Checking Adjustment 1 Open the Top cover and disconnect a staple detection lead close the Top cover 2 Hand feed a two sheet set of paper NOTE Open and close the Top cover and the Booklet maker will automatically cycle and advance staples 3 Check that the staples are formed properly according to Figures below 4 Ifa bad staple result is achieved first perform step 1 20 then proceed from step 21 5 good staple result is achieved on two sheets of paper double check the adjustment by running a 20 sheet set Bad Good Good Bad Bad Bad View from a Sop SS S side Deformed Deformed Incorrect Deformed Lengthwise Lengthwise pressure Sidewise Adjustment M 3 9 4 1 Check adjust Stapler As
116. move O ring B Loosen the allen screw underneath the O ring x1 Loosen screws and remove the motor x2 Disconnect connector D x1 3 42 29 November 2006 AREA A 3 4 21 THICK SET SENSOR Q36 View from infeed D E ot d OW 6 5 lt X View from outfeed B F Removal 1 Remove the outermost stapler head A 8 3 4 12 2 Remove nut B x1 NOTE In order to maintain distance C do not loosen screws D or E 3 Disconnect connector F E x1 Continued on next page 3 43 AREA A 29 November 2006 Replacement 1 Reverse the removal procedure Check 1 2 2 Install interlock cheater in order to operate BM 200 with Top Cover open Set trimming to off Check sensor Q36 adjustment by hand feeding sets of 80 gsm sheets A set of 32 sheets should pass but a set of 35 sheets should be stopped in the stapling area with the display showing the message Set to thick NOTE If a 35 sheet should pass quickly switch off the power in order to avoid jam clearence If not OK perform adjustment Adjustment 1 2 oY o n Ensure trimming is set to off Feed a set of 32 sheets of 80 gsm If set passes go to item 6 If set is stopped proceed with item 3 Loosen screw 0 Turn screw E 1 8 turn counterclockwise Thighten screw D Go to item 2 Feed a set of 35 sheets of 80 gsm NOTE If
117. move all connectors from the Interlock PCB x7 3 Remove screws x2 3 72 29 November 2006 PCB 3 5 CPU PCB AND COLLATOR INTERFACE PCB A A P5 4 2 1 A P9 pa ot d OW 6 5 lt X A P13 A P10 A P8 CAUTION ESD Hazard ESD Electrostatic Discharge can cause software crashes data and or communications problems Failure to use proper ESD pro cedures will cause damage to electronic components example PCBs ESD problems can be minimized by maintaining all machine ground con nections ensuring the proper handling of circuit boards and sensors Use ESD protection when working near PCBs Failure to use ESD protection is likely to result in a PCB failure 3 1 1 Remove Front cover 3 3 1 2 Remove all connectors from the PCB A x9 3 Squeeze the barbs of the pins and remove PCB A Continued on next page 3 73 PCB 29 November 2006 CAUTION ESD Hazard ESD Electrostatic Discharge can cause software crashes data and or communications problems Failure to use proper ESD pro cedures will cause damage to electronic components example PCBs ESD problems can be minimized by maintaining all machine ground con nections ensuring the proper handling of circuit boards and sensors Use ESD protection when working near PCBs Failure to use ESD protection is likely to result PCB failure 3
118. nd stop in upper position as the stapler home position sensor BM Q14 activates 6 20 29 November 2006 BOOKLET MAKING PROCESS Pre fold transport When staples are detected BM Q19 Q20 the back jogger motor BM M2 see page 6 20 moves the back jogger down to release the trail edge of the set The side guides BM M3 move out slightly Just enough to release the grip of the set but still to guide the set straight to the fold stop The stop gate solenoid BM SOL 1 moves the transport rollers upwards gripping the set between the transport roller below and idler roller on top of the set The staple stop gate is pulled down by the same solenoid and latched below the paper path The set transport motor BM M5 starts and transports the set down to the fold stop Fold stop sensor BM Q7 near the fold stop activates Side guides BM M3 move out to their initial position In case the sheet length is shorter than the distance between staple stop and fold stop i e A4 the staple stop will unlatch as soon as the set has cleared the start sensor The staple stop is unlatched by the stop gate release solenoid BM SOL2 In case the sheet length is longer than the distance between staple stop and fold stop i e A3 the staple stop will remain latched during folding until the set has cleared the start sensor BM Q4 The stop gate solenoid BM SOL 1 releases and the set transport motor BM M5 stops when the fold stop sensor BM Q7 is activated or
119. nd the brass bracket K Remove nut L and dismount the Back jogger finger amp x1 NOTE There is two different kind of Back jogger fingers One type with a bearing M and one type without a bearing N Replacement 1 Remount the Back jogger finger and tighten the nut L x1 NOTE Tighten the nut finger tight then tighten the nut 72 revolution with a 19 mm open wrench Reinstall correct Back jogger finger H 1 and J Bras bracket and the two bushings O on correct place NOTE Make sure to turn the Brass bracket correctly according to the circles in the picture Slide Back jogger arm shaft F in place NOTE Make sure to turn the shaft the correct way P Reinstall E clips E x4 Reinstall Back jogger arm module in place and tighten screws D x2 Push the spring A back with your thumb NOTE Make sure that the bearing is in the slot on the feather spring Reverse the rest of the removal procedure 3 29 AREA A 29 November 2006 3 4 11 BACK JOGGER MOTOR M2 E Removal 1 2 3 4 5 Remove Back jogger module lf 3 4 9 Remove screw A and nut amp x1 amp x1 Remove the Bracket C from the motor axel Remove connector D E x1 Remove screws E to the motor x3 Replacement 1 2 3 Reinstall screws E to the motor x3 Reinstall connector D x1 Reinstall screw A and nut B amp x1 amp x1
120. nter NOTE Use a 17 mm open wrench Adjustment 1 Useasliding calliper and check that the distance between the upper side of the clincher bar and the upper side of the sheet plate is 0 mm x 0 3 mm If not go to step 2 NOTE Check both front and rear side Loosen screws B amp x4 Adjust the sheet plate C according to step 1 Tighten screws B x4 Check adjust the Stapler assy drive bar lf 3 4 15 Check adjust Stapler head retraction distance 6 3 4 13 p EE s 39 I9 Replacement 1 Reverse the removal procedure 3 85 BOOKLET QUALITY ADJUSTMENT 29 November 2006 3 9 5 CLINCHER POINTS HEIGHT Purpose The purpose is to achieve the correct flat form of the staples and to maintain life time of the clincher points and stapler heads NOTE Adjustment of clincher points can be performed with clincher beam in stalled However if Clincher bar assembly is already removed perform Clincher bar assembly adjustment 3 4 16 Removal Front 1 Remove Stapler heads Ii 3 4 12 Adjustment 1 Presson the clincher arm where the arrow indicates 2 Press down the clincher points A to make sure that they are resting on the clincher arm 3 Check that the clincher points are flush with the upper side of the clincher beam when actuated If not go to step 4 4 Rotate allen screws B to adjust the clincher points x2 NOTE Rotate the allen screw clockwise if the clincher points
121. o perform the dead cy cling 4 Press On to start the dead cycling o Press Off to stop the dead cycling 5 2 29 November 2006 SERVICE PROGRAM MODE Interface Under Interface you adapt the BM 200 interface to the correct host machine 1 Go to Interface Press OK 2 Press Arrow to select correct host machine Press OK Changing EEPROM Values 1 Go to EEPROM values Press OK 2 Press Arrow to go to the Index to be changed 3 Press Change 4 Key in New value using the Arrow and Change button 5 Go to Store Press OK A IMPORTANT Changing EEPROM values can jeopardize the way the machine operates considerably Be sure that changing the EEPROM value is the correct solu tion before doing so If changes are made which cause the unit to operate incorrectly perform the EEPROM reset procedure 5 1 3 Using Fold Delay Fold delay is default On The fold delay indicates that the booklet is stopped between the second pair of fold rollers by the spine to make the booklet flatter It sits in that position up to about 15 seconds depending on the interval between sets If the time interval between the sets from the Collator is less the booklet is fed out sooner when the next booklet enters the booklet maker Counters Under Counters the total amount of cycles are displayed for the stapler heads Fold knife trimmer knives and cover feeder When stapler heads or the trimmer knives have been replaced the counter for t
122. oid Check fuse F3 on Transformer Procedure Power off the machine Remove connectors from solenoid SOL1 Measure on the contacts on the Solenoid Is there an open circuit Y N Reinstall connectors Measure between the violet connector on the solenoid and P2 12 on PCB MD6DC C Is there continuity Y N Replace wire harness Measure between the orange connector on the solenoid and P11 10m the interlock PCB Is there continuity Y N Replace wire Harness Replace PCB MD6DC C Replace Solenoid SOL 1 4 16 29 November 2006 FAULT CODE DESCRIPTIONS BM 033 Fault Code BM 033 indicates that the stopgate release solenoid has an Open circuit Initial Actions Make sure that the connectors are properly connected to the Solenoid Check fuse F3 Procedure Power off the machine Remove connectors from solenoid SOL2 Measure on the contacts on the Solenoid Is there an open circuit Y N Reinstall connectors Measure between the violet connector on the solenoid and P2 13 on PCB MD6DC C Is there continuity Y N Replace wire harness Measure between the orange connector on the solenoid and P11 2 on the interlock PCB Is there continuity Y N Replace wire Harness Replace MD6DC Replace Solenoid SOL2 o 50 22 Fr v BM 034 Fault Code BM 034 indicates that the Paper Infeed sensor BM Q1 is faulty Initial Actions Make sure that the Paper Infeed sensor BM Q1 is installed correctly Procedur
123. oklet maker and peripherals make sure that the Booklet maker power cord is unplugged The wall outlet should be near the Booklet maker and easily accessible Note that some components of the Booklet maker and peripherals are supplied with electrical voltage even if the main power switch is turned off If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on keep hands away from electrical or mechanically driven components OBSERVANCE OF ELECTRICAL SAFETY STANDARDS 1 The Booklet maker and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those models SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1 Dispose of replaced parts in accordance with local regulations Page intentionally blank 1 TABLE OF CONTENTS INSTALLATION PROCEDURE INS TALEATION REQUIREMENT S 1 1 1 1 1 MINIMUM SPACE 1 1 Wied IOWEIRIREGUISEMEBN S 1 2 1 2 INSTALLATION FLOW CHART 1 3 1 3 IBOOKEET MAKER INS TALLA HON 1 5 luos dA GESSOBRYGEPEBGI 1 5 3 2 INS IALEATION PROCEDURE muc DA E aT NR M utut 1 6 Tio DIOS WINES Nil Se seiten NRI p aU 1 7 QT ESO GIO cC 1 10 14 TRIMMERINSTA
124. ole G NOTE Insert the Caster the whole way When the Caster tool is in its most inner position tighten the nut D NOTE Repeat step 4 and 5 for all four of the springs Reverse the rest of the removal procedure NOTE Make sure to lubricate with Molybdenum grease according to 3 6 10 3 66 29 November 2006 AREA C 3 6 13 OUTFEED SENSOR A B 5 OW 65 o lt 1 Remove outfeed cover 3 3 4 2 Remove nut A x1 3 Disconnect connector B E x1 3 67 Page intentionally blank 29 November 2006 PCB 3 PCB 3 7 1 MD3DC PCB H H P14 H P5 H P4 E 9 83 a CAUTION ESD Hazard ESD Electrostatic Discharge can cause software crashes data and or communications problems Failure to use proper ESD pro cedures will cause damage to electronic components example PCBs ESD problems can be minimized by maintaining all machine ground con nections ensuring the proper handling of circuit boards and sensors Use ESD protection when working near PCBs Failure to use ESD protection is likely to result in a PCB failure 4 3 1 Removal 1 Remove Rear cover Milf 3 3 1 2 Remove all connectors from the PCB x5 3 Squeeze the barbs of the pins and remove PCB H Replacement 1 Reinstall PCB 2 Reconnect all connectors to the PCB x5 3 Make sure all DIP switch 2 are set
125. om the socket Hold the stapler head in place press the release lever E to release the rear end of the stapler head and lift up this end Lift out the head allowing it to rotate around the front end The stapler assem bly is spring loaded and will follow the rotation of the stapler Remove staple cartridge Look inside stapler head to locate jammed staples by eject point Remove staples if any Position the stapler head on the edge of a firm surface for example the top of a table While securely holding the head actuate the stapler up and down through full travel Perform this operation first without staple cartridge then with staple cartridge Repeat this a few times to ensure that the staples are ejected at each down movement 3 32 29 November 2006 AREA A Maintenance of stapler head The stapler head drive post on each stapler head should be lubricated every 20 00 cycles 1 F G ww ot 7 6 5 lt Put a couple of drops of oil F on each side of the drive post G 2 Cycle the stapler head a few times before installing it again Replacement of stapler head 1 Reinstall the stapler head by inserting the pin at the top of the stapler head into the stapler retraction swing arm H While rotating the stapler head insert the pin located at the rear end of the stapler head into the slots in the frame of the stapler head assembly Press down the r
126. or plug M8 Enter Service mode and start Fold stop gate motor BM M8 in check motors Measure between the orange wire M8 and the violet wire M8 PWM 36V and ground The voltage is approximately 12 VDC Y N Disconnect plug P2 from PCB B Measure between J2 2 and J2 9 PWM 36V and ground The voltage is approximately 12 VDC Y N Replace PCB Replace wire Harness Replace motor BM M8 4 13 FAULT CODE DESCRIPTIONS 29 November 2006 BM 024 Fault Code BM 024 indicates that the Staple Fold positioning motor BM M9 does not receive any displacement pulses Initial Actions Check fuse F2 on Transformer Enter the Service mode and select Staple Fold positioning motor BM M9 in check mo tors Procedure Disconnect the sensor plug Q10 to motor BM M9 Measure between the red wire Q10 and the black wire Q10 5V and Signal ground The voltage is approximately 5 VDC Y N Disconnect plug B P14 from PCB B Measure between the J14 6 and J14 8 5V and Signal ground The voltage is approximately 5 VDC Y N Replace PCB Replace wire harness Disconnect plug B P14 from PCB Check wires for Continuity Short circuit from the gray wire Q10 to B P14 7 the white wire Q10 to B P14 4 the black wire Q10 to B P14 6 the red wire Q10 to B P14 8 Is there Continuity and no Short circuit Y N Replace wire harness 1 Replace motor 2 Replace PCB 4 14 29 November 2006 FAULT CODE
127. or the motor BM M3 starts and motor the BM M3 reverses Side jogger motor BM M3 runs until side jogger motor sensor BM Q12 has counted the preset amount of pulses set by the paper size Side guides are now back in position corresponding to the paper size 6 24 29 November 2006 SPECIFICATIONS BOOKLET MAKER BM 200 Capacity Speed Sheet size max Sheet size min Paper weight max Paper weight min Automatic paper size set up in all machines from one control panel Stapler heads Staples Job saving Dimensions incl base and belt stacker H x W xD Weight TRIMMER FTR 200 Capacity Max booklet length max trimming Min booklet length max trimming Max booklet length by pass Min booklet length by pass Booklet width max Booklet width min Speed Trim length Dimensions incl base HxWxD Weight SQUAREFOLDER SQF 200 Capacity Paper size Speed Dimensions incl base HxWxD Weight SPECIFICATIONS 25 sheets of 80 gsm 20 Ib Bond Up to 3000 sets hour 320 x 457 mm 12 6 x 18 206 x 275 mm 8 1 x 10 8 300 gsm 115 Ib Cover 64 gsm 18 Ib Bond Yes 2 2 x 5000 Chisel pointed Yes 10 jobs 1000 x 1420 x 670 mm 39 4 x 55 9 x 26 4 130 kgs 287 lbs 25 sheets of 80 gsm 20 Ib Bond 220 mm 8 6 120 mm 4 7 235 mm 9 2 105 mm 4 1 320 mm 12 6 120 mm 4 7 Up to 1800 sets hour Up to 15 mm 0 6 910 x 350 x 620 mm 35 8 x 13 8
128. ove Front Cover a 33 1 Adjustment 1 Measure the wall outlet voltage 2 Transformer to the appropriate setting according to the label on the Transformer by moving cable C NOTE Do not move cable D Replacement 1 Reverse the removal procedure 3 93 Page intentionally blank 29 November 2006 FAULT CODE DESCRIPTIONS 4 TROUBLESHOOTING 4 1 FAULT CODE DESCRIPITIONS Fault Item code No BM 001 BM M1 BM 002 BM M1 BM 003 BM M1 BM 004 BM M2 BM 005 BM M2 BM 006 BM M2 BM 007 BM M3 BM 008 BM M3 BM 009 BM M3 BM 010 BM M3 BM 011 BM M4 BM 012 BM M4 BM 013 BM M4 BM 014 BM M5 BM 015 BM M5 BM 016 BM M6 BM 017 BM M6 BM 018 BM M6 BM 019 BM M7 BM 020 BM M7 BM 021 BM M7 BM 022 BM M8 BM 023 BM M8 BM 024 BM M9 BM 025 BM M9 BM 026 BM M9 BM 027 BM M9 BM 031 BM SOL1 BM 033 BM SOL2 BM 034 BM Q1 BM 035 BM Q4 BM 038 BM Q7 BM 039 BM Q8 Fault description Page No Infeed motor No displacement 4 3 infeed motor Short Dese a CERE UA 4 3 Infeed motor Open SPD o ES RUM DURO RA EXE 4 3 Back jogger motor Cycle time 4 4 Back jogger motor Short 4 4 Back jogger motor Open 11 1 4 5 Side jogger motor No displacement pulses
129. per ESD pro cedures will cause damage to electronic components example PCBs ESD problems can be minimized by maintaining all machine ground con nections ensuring the proper handling of circuit boards and sensors Use ESD protection when working near PCBs Failure to use ESD protection is likely to result in a PCB failure 3 1 1 Switch Off the Main Power Switch 2 Remove Rear Cover 33 1 3 Make sure DIP switches 1 and 4 is set to ON up position Make sure DIP switches 2 and 3 is set to OFF down position 4 Run the BM 200 MD6DC v1 00 exe file v1 00 is an example use latest version and follow the instruction in the program or according to the latest bulletin NOTE A red LED on the board will flash while downloading When download is complete LED goes out 29 November 2006 SERVICE PROGRAM MODE 5 2 3 Downloading to PCB CPU in Booklet maker CAUTION ESD Hazard ESD Electrostatic Discharge can cause software crashes data and or communications problems Failure to use proper ESD pro cedures will cause damage to electronic components example PCBs ESD problems can be minimized by maintaining all machine ground con nections ensuring the proper handling of circuit boards and sensors Use ESD protection when working near PCBs Failure to use ESD protection is likely to result in a PCB failure 3 1 1 Switch Off the Main Power Switch on the BM 200 2 Remove the Front Cover on th
130. r 3 12 29 November 2006 COVERS 3 3 7 TOP COVER ASSEMBLY 5 OW 6 5 o lt X Removal 1 Remove Front and Rear cover gii 3 3 1 Remove nuts A e x4 Remove screw B x1 and C amp x1 Move Top cover towards the front side Remove screws D x2 and adjustment plates E x2 gt n e S N Lift off the Top cover Replacement 1 Reverse the removal procedure 3 13 COVERS 29 November 2006 1 j Ue als ae Lc PN TEE LETTER a FN T SECUN E NR wo Ha TE NN ar Adjustment 1 Loosen screw D amp x1 and screws F x2 Adjust so that the Top cover rests on the rubber supports H x3 when closed 2 Loosen nuts C x4 and adjust so that the plate I holding the upper part of the Top cover lock enters the cut out in the front frame centered 3 Check that the Top cover lock works without binding Loosen screws and nuts J x2 x2 to adjust upper part in out Loosen nuts x2 to adjust lower part up down 4 Check that the Top cover Interlock switch is correctly adjusted 3 3 8 3 14 29 November 2006 COVERS 3 3 8 INTERLOCK SWITCH 16 amp 17 A C pa o E d OW 6 5 lt X Removal 1 Remove Front cover 3 3 1 2 Remove
131. r If the belt stacker is installed directly on the booklet maker no trimmer installed the stacker motor ST M1 not shown in picture starts when the outfeed sensor BM 28 activates and runs for a short while to separate the booklets on the stacker belt f fold delay is set to On the booklet sits between the second pair of fold rollers up to about 15 seconds depending on the interval between sets If the time interval between the sets from the Collator is less the booklet is fed out sooner When the next booklet activates the infeed sensor BM Q1 the fold roller motor BM M6 starts again 6 22 29 November 2006 BOOKLET MAKING PROCESS 6 3 2 SIZE ADJUSTMENT Initialization cycle Main power is switched on Staple fold positioning motor BM M9 and side jogger motor starts Staple fold positioning motor BM M9 moves staple stop and fold stop to the shortest sheets size Side jogger motor BM M3 moves side guides to the widest paper size Staple fold positioning motor BM M9 stops when staple fold home position sen sor BM Q11 is activated Side jogger motor BM M3 stops when side jogger home position sensor BM Q13 is activated When both sensors BM Q11 amp Q13 have been activated a counter for each mo tor starts and both motors BM M9 amp M3 reverse Staple fold positioning motor 9 runs until staple fold positioning sensor BM Q10 has counted the preset amount of pulses set by the paper si
132. roller 6 3 F13 BM Q10 Staple Fold positioning motor sensor loc on mot 9 6 7 D19 BM Q11 Staple Fold home position sensor eee eere 6 4 G7 BM Q12 Side jogger motor sensor located on motor M3 6 10 G2 BM Q13 Side jogger home position sensor eere eere 6 10 H2 BM Q14 Stapler home position 4 20 BM Q15 Fold knife home position sensor 16 Interlock SWILCD BM S17 Interlock BM Q19 Staple detection lead rear side 020 Staple detection lead front side EE 036 Thick Set SensOE uon T 037 Fold Gap tween a BM SOL1 Stop gate BM SOL2 Stop gate release PCB CPU FA EN RED 6 3 L6 PCB Collator Interface Sov o Lo eoe 6 4 L8 PCB Interlock D sitom ett ener me emer Mata te 6 4 L17 PCB MDODC Sages ese 6 4 E9 PCB MDODC autumni acer Ren
133. rom PCB B Measure between J2 4 and J2 11 24V and ground The voltage is approximately 24 VDC Y N Replace PCB Replace wire Harness Replace motor ST M1 4 30 29 November 2006 BLOWN FUSE CONDITIONS 4 2 BLOWN FUSE CONDITIONS WARNING ONLY USE SLOW BLOW FUSES Symptom at power on ses i Normal display function but no operations in the machine are possible 4 31 gt c o Page intentionally blank 29 November 2006 LEDS 4 3 LEDS Motor Drive PCB MD6DC in Booklet Maker amp Trimmer D15 D1 D2 D1 Yellow LED flashes when power is on The flashing indicates that a program is present and functioning Should a download fail or the 5V is missing LED would be OFF gt c o0 D2 Red LED flashes whenever information is sent or received on the Internal CAN If power is switched on but no operations are performed LED is OFF D15 Green LED permanently OFF It has no direct function in this configuration 4 33 LEDS 29 November 2006 Motor Drive PCB MD3DC in Booklet Maker D26 D1 Red LED flashes when power is on T
134. rough this procedure again until no faults are found NOTE Look through Jam History in the Service mode to locate oth er faults or to establish a pattern of repeated faults 51 1 10 1 ALWAYS POWER OFF THE SYSTEM WHEN EXITING THE DIAG NOSTIC MODE 5 20 29 November 2006 PAPER SIZE RESET 5 4 PAPER SIZE RESET If any mechanical adjustments have been carried out that effects the positio ning of side guides staple stop or fold stop this procedure must be performed If the EEPROM or the CPU PCB has been replaced this procedure must be performed During the procedure the side jogger motor and staple fold positioning motor moves between given positions to calculate this specific motors characteristics in conjunc tion with this specific machines mechanics The paper size reset procedure results in variables used when calculating the different positions for different paper sizes Should the procedure fail or not be carried out after an EEPROM reset or CPU PCB exchange The side guides will stop in the wrong position resulting in booklets not properly jogged or sets jamming between the side guides The staple and fold stop will stop in the wrong position resulting in booklets not folded in the centre booklets not properly jogged or sets jamming between the side guides 5 21 PAPER SIZE RESET 29 November 2006 Executing Paper Size Reset The side guides and stop gate must be parallel and square before
135. screws to the Fold transmission plate x3 NOTE Tighten the Fold transmission belt before tightening the screws to the tensioner then tighten the last screw x3 Tighten screws D x3 Reverse the rest of the removal procedure 3 60 29 November 2006 AREA C 3 6 9 FOLD TRANSMISSION GEAR ASSEMBLYS o E d OW 6 5 3 c C D E Remove Fold transmission belt 3 6 7 Remove E clips Remove transmission gears gt W N It is the same Fold transmission coupling assembly E on all of the Fold trans mission gear assembly s 3 61 AREA C 29 November 2006 3 6 10 FOLD DISTANCE BRACKET D A A Removal 1 Remove Fold transmission module 366 2 Remove nut to the middle bearing bracket x1 3 Remove the bearing bracket B 4 Remove Fold distance bracket C NOTE DO NOT LOOSEN OR REMOVE THE NUT D TO THE EXCENTER Replacement 1 Reverse the removal procedure NOTE DO NOT LOOSEN OR REMOVE THE NUT D TO THE EXCENTER Lubricate Fold distance brackets and Fold roller bearings 1 Lubricate with Molybdenum grease behind the Fold distance bracket and on the places marked with red 2 Perform the same lubrication on the rear side of the Booklet maker 3 62 29 November 2006 AREA C 3 6 11 UPPER FOLDER ROLLER gt o5 N 65 o lt X J
136. sembly Drive Bar 3 4 15 2 Check adjust Stapler Pressure 3 9 4 3 Check adjust Stapler Head Retraction distance ap 3 4 13 4 Check adjust Clincher points height 4 3 9 5 5 Check adjust Clincher pressure a 3 9 6 Continued on next page 3 82 29 November 2006 BOOKLET QUALITY ADJUSTMENT A C D E F Replacement Adjustment Remove Infeeder 9 9 9 Disconnect the Staple detection lead C Push down latch E and lift the Stapler head out Push the plunger C slowly so that the legs of the staple comes out about 1 2 mm E 1 J 2L 10 Insert the Multi Tool so lever J becomes pressed down 11 Reinstall Stapler head only on the pivot pin side Not in the retraction swing arm D NOTE Install the Stapler head gently so the staple legs are not touched Continued on next page 3 83 BOOKLET QUALITY ADJUSTMENT 29 November 2006 12 13 14 15 16 17 18 19 20 Staple deformed Lengthwise 21 22 23 24 Push gently on plunger C and check if the staple legs are positioned in the center of the clincher points K Check both sidewise and lengthwise NOTE Use a flash light to clearer see the alignment Loosens screws B and x2 For lengthwise adjustment turn adjustment screw H For sidewise adjustment turn adjustment screw A NOTE Push Stapler head bracket against adjustment screw A while
137. t Reinstall Fold roller sensor Q9 plate D NOTE make sure that the sensor plate is correctly installed Reinstall the Fold transmission plate NOTE Make sure that the flat of the flange bushing correspond to the flat on the Fold transmission plate Reinstall screws A B and C x3 NOTE Check adjust the Fold transmission belt tension by tightening screws C and E so you have 1mm of deflection on the middle of the belt F between pully x2 Reverse the rest of the removal procedure 3 58 29 November 2006 AREA C 3 6 8 FOLD ROLLER MOTOR M6 C o E d OW 6 5 lt X B Continued on next page 3 59 AREA C 29 November 2006 Removal 1 2 3 4 5 Remove Fold transmission belt 3 6 7 Remove screw and washer amp x1 x1 Remove bearing B Remove the Motor transmission pulley C Remove screws D x3 Replacement 1 Sr s op Je Reinstall screws 0 x3 NOTE DO NOT TIGHTEN THE SCREWS Reinstall the Motor transmission pulley C Reinstall screw and washer amp x1 x x1 Reinstall Fold transmission belt Reinstall Fold roller sensor Q9 plate NOTE make sure that the sensor plate is correctly installed Reinstall the Fold transmission plate NOTE Make sure that the flat of the flange bushing correspond to the flat on the Fold transmission plate Reinstall
138. t circuit 4 15 Staple Fold positioning Open circuit 4 16 Stop gate solenoid Open circuit ess 4 16 Stop gate release solenoid Open circuit 4 17 Paper infeed sensor is 1 4 17 Start sensor Saddle stapling is Faulty 4 18 Fold stop sensor is Faulty 4 18 Outfeed sensor booklet maker is Faulty 4 19 4 1 I 2 gt c 72 FAULT CODE DESCRIPTIONS 29 November 2006 Fault Item Fault description Page code No BM 040 BM M19 Q34Pre Infeed Motor No displacement pulses 4 19 BM 041 BM M19 Pre Infeed Motor Short 2 2 4 20 BM 042 BM M19 Pre Infeed Motor Open circuit eese 4 20 BM 044 BM Q36 Thick Set Sensor Faulty 4 20 BM 045 BM Q37 Fold Gap Sensor 4 21 BM 150 36V Input 36V
139. that the Set transport motor BM M5 has an Open circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M5 Enter Service mode and Set transport motor BM M5 in check motors Measure between the orange wire M5 and the violet wire M5 PWM 36V and ground The voltage is approximately 36 VDC Y N Disconnect plug C P2 from PCB C Measure between J2 3 and J2 10 PWM 36V and ground The voltage is approximately 36 VDC Y N Replace PCB Replace wire Harness Replace motor BM M5 BM 016 Fault Code BM 016 indicates that the Fold roller motor BM M6 does not receive any displacement pulses Initial Actions Check fuse F2 on Transformer Make sure that the Fold roller sensor BM Q9 is installed correctly ma 3 6 7 Procedure Enter the Service mode and select Fold roller motor BM M6 in check motors Does the encoder run properly Parts Catalog page 24 Item 10 Y N 1 Check fold transmission 3 6 7 2 Replace motor BM M6 1 Replace sensor BM Q9 2 Disconnect plug C P14 from PCB C Measure between J14 10 and J14 12 5V and ground The voltage is approximately 5 VDC Y N Replace PCB Disconnect plug from sensor Q9 Check wire for Continuity Short circuit from the white wire Q9 to C P14 11 Is there Con tinuity and no Short circuit Y N Replace wire Harness Connect plug C P14 to PCB Measure between the red wire Q9 and
140. the Trimmer E x1 NOTE Unless a SquareFolder SQF 200 also will be installed If so the Belt stacker cable will connected to the SquareFolder instead Remove the Trimmer Terminator plug from the Booklet maker B E x1 Connect the Trimmer Terminator plug on the Trimmer C EB x1 Remove the Interlock jumper D from the Booklet maker EE 1 m o Im Connect the Interlock jumper to the Booklet maker frame E E x1 see next spread This jumper will be stored in this area it will be needed at a later date to allow the Booklet maker to function while the Trimmer is serviced 6 Connect the communication cable to the Trimmer F x1 NOTE The communication cable you received with the Trimmer 7 Connect the other end of the communication cable to the Booklet maker G EZ x1 see next page 8 Connect the powercord to the Trimmer H E x1 9 Connect the other end of the powercord to the Booklet maker E x1 see next spread 10 Mount the cable protector J positioned as shown with two screws in the holes and route the cables inside the cable protector x 2 11 Attach the sticker Do not lift here L on the cable protector 12 Install the cable holder on the rear side of the Trimmer 13 Route cables through the cable holders on the rear side of the Booklet Maker and Trimmer D Booklet Maker without Trimmer installed Continued on next page 1
141. this procedure is carried out 3 8 1 3 8 2 poe X L Remove the two stapler heads a 3 4 12 Insert a Interlock cheater Enter the Service Program Mode Go to Paper Size Reset Press OK The text READY will be shown on the LCD display Press Run The text SIDE JOGGERS will be shown The side joggers moves in and out NOTE If this fails switch OFF and ON the main power switch and go to step 1 6 The text INSERT TOOL will be shown 7 Insert the Multi tool A according to picture below Push the Multi tool gently up against the side guide to make sure it is in con tact Press OK The text FOLD POSITION will be shown on the LCD The stop gate moves the Multi tool upwards B so the top of the Multi tool catches the clincher bar IMPORTANT If this fails the procedure must be done all over again The text REMOVE TOOL will be shown Remove the tool Press OK 29 November 2006 PAPER SIZE RESET If the purpose of performing the paper size reset procedure is strictly a result of an electronical or logical operation such as replacement of CPU PCB the procedure can be ended her by pressing ESC If any changes has been made that effects the geometry regarding the paper size such as mechanically adjusted stop gate back jogger or replaced moved home position sensor the procedure must be continued to the end 9 The text BACK JOGGER will be shown on the LCD Press RUN 10 The text I
142. tial Actions Check fuse F2 on Transformer Enter the Service mode and select Fold knife motor BM M7 in check motors Make sure that the Fold knife home position sensor BM Q15 is installed correctly Procedure Enter the Service mode and select Fold knife home position sensor BM Q15 in check sensors The Fold knife home posi tion sensor indicates 1 when the sensor is blocked and 0 when the sensor is unblocked Y N 1 Replace sensor BM Q15 2 Disconnect plug B P13 from PCB B Measure between J13 7 and J13 9 5V and ground The voltage is approximately 5 VDC Y N Replace PCB B Disconnect plug from sensor BM Q15 Check wire for Continuity Short circuit from the white wire Q15 to B P13 8 Is there Continuity and no Short circuit Y N Replace wire Harness Connect plug B P13 to PCB Measure between the red wire Q15 and the black wire Q15 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness Replace PCB Replace motor BM M7 BM 020 Fault Code BM 020 indicates that the Fold knife motor BM M7 has a Short circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M7 Run the Diagnostics again Fault code BM 021 Open circuit is displayed Y N Disconnect plug B P3 from PCB Check wires for Short circuit across leads the orange wire M7 to B P3 7 violet and the violet wire M7 to B P3 6 orange Is there Short c
143. to avoid bending front frame part Z Jt WARNING WARNING Infeed cover is very heavy and could cause injury if it falls down 3 8 o N 29 November 2006 3 3 3 INFEEDER Open the Top Cover Remove screws A x4 Disconnect connector B Lift out the Infeeder COVERS pa o E d OW 6 5 lt X COVERS 3 3 4 OUTFEED COVER B St gt 11 D Set the machine to A4 Remove Stacker module 3 8 1 Remove Front and Rear cover 3 3 1 Remove screws x2 Remove screws x2 Remove screws C x2 Turn Fold Gate D halfway to its downmost position Pull out lower end of the Outfeed Cover and lift it up enough to clear the Out feed Sensor E Pull out upper end of the Outfeed Cover and lower it until it touches the Fold Gate Turn Fold Gate to its uppermost position and remove Outfeed cover 3 10 29 November 2006 29 November 2006 COVERS 3 3 5 UPPER TOP COVER o E d OW 6 5 lt X A 1 Open the Top Cover 2 Remove screws x4 3 Lift off the Upper Top Cover B 3 11 COVERS 29 November 2006 3 3 6 REAR TOP COVER A C Remove the nut A amp x 1 Remove the screw B x 1 Remove the screws C x 2 p de Remove the Rear Top Cove
144. use ESD protection is likely to result PCB failure 3 1 1 Remove Front cover 3 3 1 2 Remove all connectors from the PCB F x6 3 Squeeze the barbs of the pins and remove 3 75 PCB 29 November 2006 3 7 7 LCD PANEL A C C D 0 CAUTION ESD Hazard ESD Electrostatic Discharge cause software crashes data and or communications problems Failure to use proper ESD pro cedures will cause damage to electronic components example PCBs ESD problems can be minimized by maintaining all machine ground con nections ensuring the proper handling of circuit boards and sensors Use ESD protection when working near PCBs Failure to use ESD protection is likely to result a PCB failure fl 3 1 Remove Front cover 3 3 1 Disconnect connector x2 Remove nuts B x 2 Remove nuts and plastic washers C amp x4 x4 Remove plastic washers D between the button PCB and display lt lt x4 Mu Ini 3 76 29 November 2006 3 8 STACKER 3 8 1 STACKER MODULE STACKER pa 5 OW 65 5 o lt c 1 Loosen screws A to the Stacker Module P x2 2 Disconnect the connector to the Stacker Module 1 3 Lift off the Stacker Module 3 77 STACKER 29 November 2006 3 8 2 STACKER MOTOR M1 B D Removal
145. y blank 29 November 2006 SPECIAL TOOLS AND LUBRICANTS 3 2 SPECIAL TOOLS AND LUBRICANTS 3 2 1 SPECIAL TOOLS In order to facilitate the service of the BM 200 Booklet Making system there are a few special tools needed Where part number is written it can be purchased from your supplier Multi tool Included in BM 200 Part No 781032 p d OW 6 5 lt X y B Interlock cheater USB converter Software loading cable Included in BM 200 Not included in BM 200 Not included in BM 200 SQF 200 Part No 103 purchase locally Part No 770010 101565 Cheater location BM 200 infeed side view SQF 200 infeed side view Two Cheaters one for BM 200 and one for FTR 200 are stored inside the panels between collator and BM 200 The SQF 200 Cheater is stored on the inside of the front side machine frame 3 3 29 November 2006 For the BM 200 Booklet Making system not to be interlocked interlocked 36V interrupted the Interlock switch must be activated and the Interlock magnet must be blocked with a metal Use the Cheater to override the interlock for running the system with open top covers On the BM 200 and FTR 200 1 Hold the Cheater above the interlock so the arrows meet 2 Putin the right end in the slot so it hooks under the bracket 3 Push the Cheater down and to the left so it latches in place i L gt BM 200 view towards user interface FTR 200 view from outf
146. ystem make sure that the Trimmer is parallel to the Booklet Maker E 2mm If necessary adjust by turning the two nuts F on the outfeed side of the Trimmer 29 November 2006 TRIMMER INSTALLATION 1 4 4 DOCKING Docking procedure o S 72 B Trimmer interior towards D A D Booklet Maker C 1 Loosen nuts A to the Locking bracket B x 2 2 Dock the Trimmer to the Booklet maker 3 Secure the Trimmer by lifting the Locking bracket B and tightening nuts A 9 x 2 NOTE Make sure that the Trimmer locking bracket B locks in the outer slot C on the positioning pin TRIMMER INSTALLATION 29 November 2006 Install Trimmer fan T 4 CUP aom j Die i 4 F Trimmer interior towards Booklet Maker 1 Install Trimmer fan A by hanging it onto the position pins B inside the Trimmer 29 November 2006 TRIMMER INSTALLATION Install Belt stacker 9 amp 72 Trimmer 1 Loosen screws amp x 2 on the Trimmer NOTE Unless the SquareFolder SQF 200 will be installed If so the Belt stacker will be installed on to the SquareFolder instead 2 Install the Belt stacker on to the Trimmer 3 Secure the Belt stacker with the screws x 2 TRIMMER INSTALLATION 29 November 2006 1 4 5 CONNECTORS 1 Connect the Belt stacker cable A to
147. ze Staple stop and fold stop are now in the correct position corresponding to the paper size selected Side jogger motor BM M3 runs until side jogger motor sensor BM Q12 has counted the preset amount of pulses set by the paper size Side guides are now in correct position corresponding to the paper size selected as 6 23 BOOKLET MAKING PROCESS 29 November 2006 Changing paper size New paper size is selected on the Staple fold positioning motor BM M9 and side jogger motor BM M3 starts oide jogger motor BM M3 runs in the direction towards the new paper size Side jogger motor sensor BM Q12 counts pulses from the previous paper size to the new paper size and stops the motor BM M3 when the correct amount of pulses are received Side guides are now in correct position corresponding to the new pa per size selected The staple fold positioning motor BM M9 movement depends on the change in paper size to take out mechanical play f changing to a longer paper size where the total length is 30 mm longer or more staple fold positioning motor BM M9 runs in the direction towards the new paper size Staple fold positioning sensor BM Q10 counts pulses from the previous pa per size to the new paper size and stops the motor BM M9 when correct amount of pulses are received Staple stop and fold stop are now in correct position corre sponding to the new paper size

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