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Supplemental Service Manual

1. Bushings the shafts are supported in the machine and spin within oil impregnated bronze bushings These automatically release oil to the shafting as required They are stressed in the unit at less than 30 of their rated load The bushings have proved so durable that we have not yet replaced one as failed in the field vd t lt Framework once again we take the stand that enough is not enough As with the balance of the machine technical testing is carried out and the results used to choose materials In this case we use materials rated at triple the rated requirements We have never experienced the failure of a frame component We tie all the parts together with rigid cross shafts On our two larger models we weld the stand out of heavy section angle rather than making it out of stamped thin steel The result is quieter more solid running equipment lt Rollers all are solid urethane Impervious to cleaning chemistry chemicals in the paper Such as the ones in carbonless paper and whatever else may contact them They are also capable of being machined to more precise tolerances are more resistant to abrasion and quite simply last longer While we do encounter normally expected wear on the feed tires the main rollers are another of our never replaced parts lt Electronics so reliable we back them for five years see our warranty for details Enough said If one ever fails the self diagnostic features identify the pr
2. DP3 SET FWD The GW 6000 performs a limited set of self diagnostics on power up A full set of diagnostic utilities is accessed by a manufacturing test mode The system indicates paper error conditions along with hardware faults by displaying a message on the LED display during operation All settings are simple enough for the customer to be coached through via telephone We however recommend that they only be done on site by the dealer 4 7 OVERVIEW Access to all settable parameters is available through the keyboard while in the main operating menu This is the menu display when the machine is first turned on If you are not at this point press STOP as often as required to return to the main operating menu When at this point press STOP and while holding it down press and 2 at the same time The display will read tESt01 The test program is one of 10 available items Each of the others is accessible by scrolling with the SET FWD or CLR BWD buttons and then START will allow you to enter that specific item number 13 4 8 INDIVIDUAL ITEMS tESt01 TEST RUN ee When selected this program will run the default factory program The lli lli motor will run stop start and the heads will fire simulating a standard 10 Il LL run This is useful after replacing a component on the machine and ANE NER ALD EL testing its correct installation We run each machine for thr
3. Serew 200050 x Heit Adjustment Soren i x 21 04 X Solenoid Gable 2515594 x ein Board Connector K 39 DESCRIPTION 100 150 I x Switch Plate Circuit Mount Tai are enteral impression C Jit oh esu ma ove wer Xx P _ Jj 50 007 Brew x p p sns X K x x Dive Unit oun SB OE x x X p mase KK p p Sha res X K x x En Sate KR a Be ensioner x ee XC x 50 037 GW JOPJOP Xx x Regular Caster Wheel JOP JOP e lt Looking Caster Wheel X ormes 60 001 GW X X Conveyor Outfeed Plate 25 009 GW 25 012 GW 30 025 GW 30 027 GW 30 037 GW 40 003 GW JR X X X 5 E ES ug X 60002 GW K Bock operators side K Bick nonoperorssie _ K nam Pile Tray Moun
4. 21 2283 Argentia Road Mississauga Ontario Canada 5 572 Tel 905 858 7663 Fax 905 858 4419 Toll Free 1 8 00 265 3376 Website www graphicwhizard com Email contact graphicwhizard SERVICE MANUAL VERSION 1 0 TABLE OF CONTENTS Technical Highlights 1 0 Specifications 2 0 GW Junior 2 1 GW Junior Circuit Board Values 2 2 Troubleshooting 2 3 GW Junior Parts Diagram 3 0 GW 3000 Operation 3 1 Running a Job 3 2 Stopping a Job 3 3 Clearing a Job 3 4 Changing and Programming a Job 3 5 Error Codes 4 0 GW 6000 Operation 4 1 Running a Job 4 2 Stopping a Job 4 3 Clearing a Job 4 4 Changing and Programming a Job 4 5 Speed Control 4 6 GW 6000 Software Set up and Diagnostics 4 7 Overview 4 8 Individual Items 4 9 GW 6000 Error Codes 5 0 GW 8 12000 Operation 5 1 Running a Job 5 2 Stopping a Job 5 3 Changing Programs 5 4 Programming a Job 5 5 The Batch Function 5 6 The Repeat Function 5 7 Motor Speed Control 5 8 GW 8 12000 Software Set up and Diagnostics 5 9 Overview 6 0 7 0 8 0 5 10 Individual Items 5 11 GW 8 12000 Error Messages Circuit Boards Layout and Diagnostics 6 1 GW 3 6000 Circuit 6 2 GW 8 12000 Circuit 6 3 GW 3 6 8 12000 Circuit Diagnostics GW Parts List Parts Diagrams 8 1 Feed Tray Assembly 8 2 Exit Tray Assembly 8 3 GW 3 6 8000 Operator Side 8 4 Electric Solenoid Drive Unit 8 5 Pneumatic Solenoid Drive Unit 8 6 Accessory Holder 8 7 Blade Placement on Boss Wheel 8 8 GW 12000 Feed Dr
5. 50 019 G lt i 70 014 GW 96 013 GW 94 014 GW 7 227 96 025 GW 2 50 009 GW 96 012 GW Es 94 013 GW 96 009 GW 7 E 70 003 GW 3D E 90 012 GW 96917 10 027 GW 5 T NN 96 023 GW v 90 002 GW 10 027 GW 90 082 GW lt RER K S 96 0 ER 10 032 GW 54 E 60 007 GW E 90 007 GW 50 019 GW 50 019 GW 8 9 GW 12000 Structural Parts Diagram 90 001 GW 10 030 GW 10 090 GW S 10 029 GW g 10 024 GW 8 10 025 GW 7 SH A 10 026 GW 50 014 GW 10 030 GW 10 024 GW amp 10 025 GW 10 058 GW 10 029 GW 10 026 GW 10 027 GW lt 50 010 GW 10 029 GW D gt 50 011 GW 10 030 GW _ SP 10 030 GW e 10 024 GW amp 10 025 GW 10 025 GW 10 026 GW 10 029 G d Gy 15 036 GW 2 10 029 GW e 10 031 GW gt 10 027 GW DE 10 030 GW 10 029 GW N N 50 020 GW 8 10 GW 3 6 8000 Shaft Placement 46 8 11 Conveyor Outfeed Assembly 50 018 GW gt 60 009 GW 60 015 GW 10 027 GW 90 01 60 012 GW np 10 027 GW 9 ANS b 60 011 9 10 026 GW x 60 016 GW 22 60 002 60 017 GW 60 017 GW 60 016 GW 60 006 GW gt 60 004 GW R 60 014 GW GW 60 013 GW 60 003 GW 60 001 GW 60 017 GW 60 017 GW 60009 GW 10 026 GW 10 027 GW 47 48
6. 90 015 GW N zh 10 023 GW 10 030 GW N 90 002 GW o 90 062 GW 90 082 GW 8 3 GW 3 6 8000 OPERATOR SIDE 43 Ce January 1997 BI 10 044 GW 10 043 GW 10 040 GW N lt SY 10 042 GW 10 041 GW A gt 7 50 040 GW 15 052 GW S 15 039 GW 90 054 GW 10 054 GW gt 10 011 GW B 8 4 ELECTRIC SOLENOID DRIVE UNIT 15 072 GW 10 040 GW SY 9 10 042 GW lt 10 041 GW gA IQ 10 045 GW 10 046 GW a E 2 100506 0 7 15 052 GW E 10 071 Gw 15 039 GW Z 96 070 BW 90 055 GW 10 011 GW O 8 5 PNEUMATIC SOLENOID DRIVE UNIT 94 072 GW 44 lt 90 054 GW 10 054 GW lt gt S 8 6 ACCESSORY HOLDER Pressure Adjustment Screw 10 085 GW Locking Thumbnut Position Locking 10 023 GW Set Screw 15 038 GW Perf Slit Score Blade 10 095 GW 3 4 Snap Ring Blade Hub 10 011 GW 8 7 Blade Placement on the Boss Wheel Perf amp Slit Blades Ride On The Flat Surface Of The Boss Wheel Narrow Score Blade Rides Boss Wheel In This Groove 10 090 GVV A d Boss Whee Shaft 50 014 GW Regular Score Blade Rides In This Groove 8 8 GW 12000 FEED DRIVE COMPONENTS 70 008 GW 0 60 96 019 GW 45 96 024 GW 50 019 GW Ne hx 70 003 GW 10 021 GW 50 017 GW 70 006 GW 70 015 GW
7. start new NEW modify it MOD PERF SHIELD RED PHOTOCELL GRN ON PERF SHIELD OPEN ON NO PAPER IMPRESSION 1 a NO FUNCTION This selection is done with the corresponding function key lt lt lt and gt gt gt respectively When modifying a program previously programmed hits can be removed from the program while additional hits may be added Once you make your selection the machine will instruct you to INSERT PAPER PRESS START The LCD display will then show the following PERF SHIELD RED PHOTOCELL GRN IMPRESSION 1 ON PERF SHIELD OPEN ON NO PAPER NO FUNCTION DISPLAY FUNCTIONS DISPLAY xxx solenoid program number ccccc current paper position in motor steps from paper lead edge lt lt lt motor moves in forward direction gt gt gt motor moves in backward direction full block character displayed when hit programmed solenoid channel 1 head 1 3 solenoid channel 1 head 2 SOL3 C2 solenoid channel 2 head 1 4 solenoid channel 2 head 2 SOLA The sheet you inserted is automatically moved to position 75 Position 0 is the lead edge of the sheet passing the photocell Position 75 is the first location that an entire number will print on the paper Note Each step represents approximately soth of an inch The first two function keys step the paper either forward or backward Note you cannot back the
8. 07 CHANNEL 2 HOT e Machine has been running for a while and the solenoids have heated up Y Turn the machine off to allow the head to cool down 08 AC LINE VOLTAGE OUT OF Check line voltage OPERATION RANGE 09 MOTOR VOLTAGE OUT OF e Motor has been running for a while and needs cooling down RANGE e _ board needs replacing 10 EEPROM ERROR e component problem has occurred 10 4 0 GW 6000 OPERATION e SAFETY PHOTOCELL IMPRESSION CONTROL O O The operating keyboard is comprised of six LED segments various buttons and a Impression Control which consist of one potentiometer knobs that control the crash strength of the numbering heads and can be adjusted to best suit the requirements of the job For example you may require stronger crash numbering for carbonless sets than for single sheet bond paper This adjustment can be done while the machine is stopped or running The four buttons under the LED display will perform whatever function is shown directly on them SET FWD Is used to set up a numbering job and incrementing the motor in a forward direction CLR B WD Is used to clear programs and increment the motor backwards FN S Q H1 Is used to control head number one which is the e head closest to the operator IMPRESSION H2 Is used to control head number two which is the head furthest away from the operator START Is used to start the machine STOP Is used to stop the
9. PV Solenoid Board Exchange ESTI D ETE il T al p p p Suppor Sha 014 Boss Bearing Support Assembly EX P x poa p K P X SES g ICPU Display Board Exchange EN Red Screen Cover LV Solenoid to MSTP Board Power Cable Drive Unit Connection Mount Plate 96 009 GW 96 012 GW 96 013 GW 96 015 GW X Register Board Register Guide Register Board Ball Holder Safety Shield w Shaft X Safety Switch Harness 12k 96 017 GW 96 018 GW 96 023 GW Register Board Cross Shaft Supports Register Board Bearing Blocks Register Board Conveyor Spool Non Operator Side Stock Guide Ei BEI S E fea ESE ies 96 026 GW Green Alternate Push Button Switch O O cO cO o cO j GO o o O O O O O O O O O ojlo O O O O O O O NI N oy BY o o o o ol o o o o o o gt gt 1 42 8 0 PARTS DIAGRAMS 10 018 GW 10 017 GW 10 019 GW 10 018 GW 10 020 GW e A 8 1 FEED TRAY ASSEMBLY 10 055 GW 10 057 GW _ 10 056 GW 8 2 EXIT TRAY ASSEMBLY 22 10 022 GW
10. X X C Resse oer wi TAGE Blade X X P B X Kk BweMombwbem f accessory Hoerwiderwes B X X eri Tre K K x Weed bera K K eres K K X eae Blade 6 TPI Perf Blade k X P Pe Pea Bade 10092GW K X x x x 10 096 GW x X X X Microperf 42 TPI Blade 10 097 GW x X X X X X Microperf 72 TPI Blade K X xk x x x K X xk K x x 10496541 x x K K X Narrow Score Bade x X X X X Kx Double Score 1 4 separation w Holder amp Boss 150554 x K x X X zoz 15054 x x x X X 202 K X X X Keyed Dive Unit Mount Shaft K X x K 15 038 GW jx X x X 5 6 DoggedSetScrews 15 039 GW X X X Drive Unit Mount Block left right pitch control 1505260 X X X Sonoda Mount wiube 157204 K X Complete Deve Unt K K Complete Dive UnitwReverse Ang Head x 20 002 GW X Register Lay Sheet 200050 X x Sot Pate wim 2000530 X mwwrow x Forwarelack
11. continuously holding it down will run the motor at SET UP SPEED If START is pressed the machine will run continuously only in the FORWARD direction and the Motor Period will change with the H2 Impression Dial If the SETUP button is pressed the motor will cycle on and off every 10 seconds PER 00444 MOT V 003 FWD OFF LO 8 TEST POT AND KEYS PT1 aaa XXXXXXXXXX This test program will allow you to check the functionality of all the keys on the display and also the Impression Control Dials The display will show two K lines PT1 represents the ADC value of Head 1 and when the Impression Control Dial for the head is turned the values beside PT1 will accordingly increase or decrease The same is done for the Impression Control Dial for Head 2 The X s to the left will disappear any time a key on the display pad is pressed 9 LOAD DEFAULTS LOAD DEFAULTS This function allows the loading of the entire factory set programs and PARM PGMS EXIT parameters into the EEPROM All the existing EEPROM data will then be overwritten PGMS will clear all this existing solenoid programs from the memory and load the factory set solenoid programs from 01 100 When PARM or PGMS is pressed a secondary confirmation screen will be displayed 27 Once PARM or PGMS is selected the confirmation screen will display which CONFIRM LOAD DEFAULT was selected on the bottom left and then accordingly press F1 for
12. machine Once you have plugged the machine in turn the on off switch to the on position The LED display will be blank for a second the two lights for the safety lid and photocell will light up The system will do a check on each LED line segment and then look like the above The Sprint 6000 does systematic error checks if it detects an error it will display a numeric value 4 1 Running a Job The machine is capable of storing a maximum of 1 job with 10 hits for recall and future use Ensure that there is paper in the feed tray first Pressing the START button will automatically begin the program that was previously programmed in the memory 4 2 Stopping a Job There are two methods of stopping the machine 1 Once the program is running pressing the STOP button will cause the machine to finish the stock it is currently working on move the next stock into the starting position and then stop the motor 11 2 If you want to stop the machine while stock is still left in it simply hold on to the stock in the feed tray After about one second the machine will automatically stop since it is no longer seeing any new sheets This is how it also stops when all of the stock in the feed tray is gone 4 3 Clearing A Job To completely clear a program from the memory insert a paper in the feed tray Press the SET FWD button The paper will then feed through and stop at 75 Press the CLR button and hold it down next pr
13. may not be correct contact at the Footpedal s contact point if there are no breaks in the line Remove the two side screws from the footpedal but carefully because the top is sprung The contact point will now be exposed There may be corrosion or dirt at the contact point With very fine sandpaper clean the points reassemble and test If after the above is performed and you still do not locate the problem the Footpedal may require replacement In the bottom right of the Circuit Board is a 2 Pin Impression Control Connector This connects to the mpression Control on the Operating Panel Make sure that the Impression Control is not completely counter clockwise as this may close the circuit As well the Impression Control Potentiometer on the circuit board is used to change the Impression Control range according to the line voltage and again it should not be fully counter clockwise 2 3 GW JUNIOR PARTS DIAGRAM 10 044 GW o SN 10 040 GW IND s gt 10 042 GW 10 043 GW S 10 041 GW 20 005 GW 10 053 GW 25 004 GW Kc lt 10 052 GW O 10 054 GW 40 10 011 GW 25 009 GW 20 002 GW 20 003 GW gt 20 010 GW 3 0 GW 3000 OPERATION e SAFETY PHOTOCELL IMPRESSION CONTROL 9 O The operating keyboard is comprised of various buttons and a Impression Control which consist of one potentiometer knobs that control the crash strength of the numbering heads and can be adjusted to best sui
14. motor is running in high low current when the light is on it is in high current To toggle from high to low press H2 To run the motor must be online pressing START will let you run the motor continuously If you press and hold down the H1 button then press H2 the motor will run for 10 seconds then turn off for one second and repeat the whole cycle again lt This will test the stepper motor motor direction motor on line off line If the motor is running STOP will stop it To exit this item press STOP tESt08 TEST LEDS i gt sx This function will test all the following indicators individual digit LIED dao DT DI segments entire digits decimal points photocell perf shield LEDs L I Pressing SET FWD will cycle all the segments in DP5 and DIGS Each press of the CLR BWD will cycle through DIG4 0 DP4 0 one digit with each digit displaying 8 triggers the photocell LED 2 the perf shield LED 15 To exit this item press STOP tESt09 TEST POT KEYS This program allows individual testing of all keys and impression pot FI Each key will turn on a decimal point while pressed SET FWD turns Ili IZ F on DPS while pressed CLR BWD turns on O w O r r DP4 HI turns on DP3 H turns on DP2 STOP turns on DP1 and START turns on DPO T
15. remain intact 1 The following are the Mode Program Setup solenoid program constraints There is a maximum of 1 hit position in a program SOL2 can only be enabled when SOL hit data exists otherwise H2 key presses will be ignored Modification of existing hit data can only occur while at the hit position The user shall not be allowed to step backward past paper stop position The perf shield shall be closed before entry to Mode Program Setup An open perf shield condition with paper loaded disables the motor and solenoid operation until the perf shield is closed 3 5 Error Codes ERROR BLINK ERROR CONDITION NUMBER CONDITION 01 PAPER JAM e Paper has lodged itself above the photocell and beneath the reflector Y Remove paper sideways do not pull up against the reflector e Dust has accumulated over the photocell Y Blast the groove below the reflector with air e Photocell needs readjustment 02 CH 1 OPEN e Head 1 is not plugged into channel 1 03 CH 1 SHORT e The solenoid has failed and replacement is necessary 04 CH 1 HOT e Machine has been running for a while and the solenoids have heated up Y Turn the machine off to allow the head to cool down 05 CH 2 OPEN e Head 2 is not plugged into channel 2 e program being ran is using two heads and there is only one drive unit Y Reprogram using Head 1 06 CHANNEL 2 SHORT e The solenoid has failed and replacement is necessary
16. the machine down e Power up the machine again e If still encounter EEP errors replace PSTP board e Errors During Program Running e Paper Errors e Generally paper errors can be cleared by hitting STOP e The error message displayed should be looked up in error messages table to identify the cause of the problem in order to fix it e Solenoid Errors e Generally solenoid errors can be cleared by hitting STOP e The error message displayed should be looked up in error messages table to identify the cause of the problem in order to fix it 37 7 0 GW PARTS LIST JR 3K 6K 8K FM FM DESCRIPTION 100 150 10 001 GW x Red Preinked Pad w holder x X X Preinked Pad wiholder X XXX 10 004 GW X X X X Felt Insert 10 006 GW X X X X Black Ink 4 oz bottle Howrow X Kk X x K pp K p 10 009 GW X X x x x 5 32 Hexdriver 10010 GW Ying Pers 0 011 GW X X 34 Snap Ring 10 012017 X Reverse Numbering Head 8 dois 200p 10 01201 X Numbering Head 6 dois 500p 10014 GW Condensed Reverse Numbering Head diais 24100 10445 50 Stamp 10 016 GW Washer 10 07701 10 018 GW Feed Tray Side Guides 10 019 GW Feed Tray Slot Cover 10 020 GW Locking Wingnuts 10 021 GW Feed Platen Retarding Strip 10 022 GW Feed Shaft Adjust
17. AMMABLE PARAMETERS 1 1 1 2 2 2 2 _____ 3239 EA 4 4 4 4 4 4 Memory Errors SETUP MODE SOLENOID PROGRAM HIT INDEX OUTOFRANGE SOLENOID PROGRAM NUMBER IS CORRUPT Reserved 60 SCI Errors 76 81 G ______ MSTPRECEVEFRAMINGERROR 8 MSTPSCIERROR REPORTED IS UNDEFINED Hardware Errors 5 0 GW 8 12000 OPERATION IMPRESSION 1 FLASHES IF RAM ERROR FLASHES IF LCD ERROR NO FUNCTION A E The operating keyboard is comprised of a two line LCD display various buttons and two Impression Controls which consist of two potentiometer knobs that control the crash strength of the numbering head and can be adjusted to best suit the requirements of the job For example you may require stronger crash numbering for carbonless sets than for single sheet bond paper This adjustment can be done while the machine is stopped or running The four buttons under the LCD display will perform whatever function is shown directly above them on the bottom line of the LCD display They may not always be active this is the case for the other buttons as well Three specific function buttons SET UP BAT REP are situated beside the display A numeric keypad an ESC escape accept START and STOP button rounds out the rest of the keyboard The ESC button can be used at almost any time except during actual running in order to return to th
18. K X N I AI K K KK p oler K K C __ recesso eura Seppe Asomby sona p Sate Sea ES K Satay Sich wharness K K K ALIS 90 025 GW X MSTP Board 3k X e sme _ SSS X U IAE Stara Boar eR ta Samo Boa 90 029 GW X 90 030 GW 90 031 GW ICPU Display Board x X TOP Display Board Exchange X KK fj X X X X 12V Cooling Fan X Print Head Mount Sorews X Pint ead Rotation Screw 1 MST Board 120V Coneco Board 220V gt lt Ferio STP Board abe ECT Connection Board to Female Tema 41 fei a AE ss PART JR 3K 6K 8K FM FM DESCRIPTION 100 150 x X Xx x X X E __ Paste Etica Guard X IX x 92 025 GW MSTP Board ESTU K X p use _ k eee EST K X HW Votage Boar 202 ex X X
19. LD RED PHOTOCELL GRN IMPRESSION 1 ON PERF SHIELD OPEN ON NO PAPER WILL EXIT TO Mode Idle SOL CH1 ADJUST PULSE WIDTH IMPRESSION 2 SOL CH2 ADJUST PULSE WIDTH DISPLAY FUNCTIONS DISPLA Y ssssss motor speed bar graph PGMxxx solenoid program in RAM paper count decrement motor speed 7 increment motor speed HALT motor emergency stop exit to Mode Idle aaa CLR clear paper count normally aaa BAT Display current batch size when batch mode is enabled KEYPAD FUNCTIONS STOP START DECREMENT MOTOR SPEED INCREMENT MOTOR SPEED MOTOR EMERGENCY IF BATCH SIZEIS ZERO Complete numbering STOP Eject current sheet Exit to Mode Idle CLEAR PAPER COUNT Stop motor ELSE Exit to Mode Idle DISPLAY BATCH SIZE SETUP BAT RE EXT A IT J 19 5 Exit to Mode Idle Exit to Mode Idle Exit to Mode Idle STOP MOTOR EMERGENCY STOP Fai to Modes Idle Exit to Mode Idle ELSE DISPLAY BATCH SIZE DIG 0 9 MOTOR EMERGENCY STOP Exit to Mode Idle 5 2 Stopping a Job Here are methods of stopping the machine 1 Once the program is running there are several built in safety emergency stops Pressing the STOP button any of the digits 0 9 F1 STOP ACC ESC REP and if the Batch size is 0 BAT will cause the machine to finish the stock it is currently working on move the next stock into the starting position and then stop
20. STP board LD2 Secondary 5V Supply Indicator e This LED indicates whether the secondary 5V supply is alive lf this LED is not on then the possible causes are Machine not turned on e AC power connector not plugged into J2 PSTP board or cable broken e Jumper not in J5 or incorrect jumper in J5 black for 110VAC purple for 220VAC e X2 VR2 or VR1 not functioning or short on S 5V line replace PSTP board LD3 Secondary 12V Supply Indicator e This LED indicates whether the secondary 12V supply is alive lf this LED is not on then the possible causes are Machine not turned on AC power connector not plugged into J2 on PSTP board or cable broken e Jumper not in J5 or incorrect jumper in J5 black for 110VAC puple for 220VAC e X2 VR2 not functioning or short on S 12V line replace PSTP board LD4 Motor Voltage Supply Indicator e This LED indicates whether the motor voltage supply is alive This LED should only be on when the motor is brought online e fthis LED is not on then the possible causes are e Motor not online 320V supply not functioning verify that LD1 is on e motor switching supply not functioning replace PSTP board 32 LD5 Primary 12V Supply Indicator e This LED indicates whether the primary 12V supply is alive fthis LED is not on then the possible causes are Machine not turned on e AC power connector not plugged into J2 PSTP board or cable broken e Jumper
21. Screw 10 023 GW Locking Thumbnut 10 024 GW 10 025 GW Roller Hub 10 026 GW Roller Shaft 10 027 GW 3 8 Set Screw Collar 10 028 GW Shaft Bushing 10 029 GW Feed Shaft Bushing w Spring 10 030 GW 10 031 GW 10 032 GW 10 033 GW 10 034 GW 10 035 GW 10 040 GW 10 041 GW 10 042 GW 10 043 GW 10 044 GW 10 045 GW 10 046 GW 10 047 GW Regulator Manifold Gauge Assembly w hose 10 048 GW 3 8 Hose 4 length 8 Hose Quick Connect 10 050 GW 1 4 Hose 4 12 length 10 051 GW 74 Hose Quick Connect 10 053 GW gt x HI LI ET Roller Tire feed main exit Shaft Bushing w Spring Solid Bottom Roller Main Platen Crash Pad Main Platen Main Platen Grommets Main Platen Mount Brackets Hand Knob 5 16 Disc Spring 5 16 Flat Washer Solenoid w plunger Solenoid plunger Pneumatic Cylinder Pneumatic Valve Controller 10 049 GW Drive Unit Cover PART JR 3K 6K 8K DESCRIPTION 100 45 10 054 10 054 GW a XIX x Print Head Mount Head Mount CE K K X p agri ray Se Guides KK PP Rape 10 059 GW x X X X 120V Modular Line Cord SS IE Fase 10 065 GW 250V Slow Blow Fuse Op S E Fuse p RC X K C impression Gant Dal Kb AU KK
22. W VOLTAGE SOLENOID CONNECTION BOARD TO FEMALE TERMINAL 96 071 GW FILTER TO MSTP BOARD CABLE 90 064 GW 120 V 90 060 GW 220 V MSTP BOARD MSTP BOARD CONNECTOR CONNECTOR 90 061 GW FRONT a 94 029 GW o EIA Ooo aa O o sev BOO o 8K SAFETY SWITCH WIHARNESS 90 016 GW 12K SAFETY SWITCH WIHARNESS 96 016 GW PHOTOCELL gl ASSEMBLY 12 V COOLING 90 067 GW FAN 90 032 GW PHOTOCELL VOLTAGE POTENTIOMETER amp E TELEPHONE CABLE 90 030 GW 31 r H OLD9 1 105 9 LD6 MSTP EPROM 92 026 GW MSTP BOARD 92 025 GW 92 025 GW X STEPPER MOTOR WIHARNESS 90 005 GW GW 3 6 8 12000 CIIRCUTT DIAGNOSTICS Purpose e This document provides a brief overview of the functions of the LED indicators on all GW boards e how to correct if possible error messages on the displays LED Indicators PSTP Board e All LEDs have a brief one word indicator on the silkscreen beside the LED This describes the main function of the LED e 101 320 Supply Indicator e This LED indicates whether the 320V supply is alive e lf this LED is not on then the possible causes are in order of probability e Machine not turned on Fuse Blown AC power connector not plugged into J2 on PSTP board or cable is broken Jumper not in J5 or incorrect jumper in J5 black for 110 VAC purple for 220VAC Bridge doubler not functioning replace P
23. Yes or F2 to aaaa YES BAC go back 10 TEST FORMAT EEPROM FORMAT EEPRO This function will erase all programs and set the factory defaults It will totally erase the EEPROM and reprogram all the programmable parameter EXT defaults along with the solenoid program defaults CLR will load an empty program into all the program locations of the EEPROM it will then display a secondary CONFIRM FORMAT screen before erasing the existing data when formatting an update completion bar will indicate the progress Once format is complete the screen will display FORMAT COMPLETE Note that once formatting has commenced the user cannot abort formatting operation 28 5 11 GW 8 12000 ERROR MESSAGES 2 PINSERTPAPEER APAPEROUTCONDITIONEXISTS PAPERTOOLONG A PAPER LONG CONDITINOEXISTS _______________ A PAPER SHORT CONDITIONEXISTS Solenoid Errors Motor Errors EEPROM Errors UNABLE TO WRITE TO EEPROM Memory Errors Hardware Errors MOTOR VOLTAGE ERROR MOTOR VOLTAGE OUT OF OPERATION RANGE SCI Errors SCI ERROR 71 ICPU SCI RECEIVE OVERFLOW ERROR ICPU SCI TRANSMIT ABORTED MSTP SCI RECEIVE TIMEOUT ERROR MSTP RECEIVE OVERRUN ERROR 29 6 0 CIRCUIT BOARDS LAYOUT AND DIAGNOSTICS BLUE LINE FILTER 90 063 GW BROWN HIGH VOLTAGE SOLENOID BOARD 90 028 GW 90 028 GW X SOLENOID CONNECTION BOARD FEMALE TERMINAL 90 069 GW l s BLUE BCU ro
24. a hit exists in the program Changing the position of a hit can be done by scrolling SET FWD or CLR BWD to where the previous hit existed Once there the head will fire and you will have an h displayed in DIG 4 the numbers indicate the stepper count position You will also have either DP 1 and or DP 0 lit depending on which numbering head was activated Pressing Either or H2 will toggle the lights off or on When DP 1 or DP 0 is off it indicates there is no longer a hit programmed at that position Now by scrolling with the SET FWD or CLR BWD buttons you can reposition the number hit Once all is set press START and SAVE will display in DIG 5 2 and the current sheet will eject The machine will go into the idle mode This will show DIG 4 0 as 0 s Any numbers on the display will be a paper count pressing the CLR BWD button will clear this back to zero To run the job insert paper into the feed tray and press start 2 4 5 SPEED CONTROL The GW 6000 is equipped with three speeds Slow speed is the default when you first run the program While the program is running press and or H2 you will notice on the far left side of the display vertical lines Three of these lines indicate high speed two for medium and one for low speed 4 6 GW 6000 SOFTWARE SET UP and DIAGNOSTICS PERF SHIELD RED PHOTOCELL GRN IMPRESSION F
25. bort the pulse width changes and exit to the Manufacturer Test Mode display screen Pressing START will store the new pulse width changes in the EEPROM the display will flash SAVE and the machine will exit to the Manufacturer Test Mode display screen tESt06 TEST SOLENOIDS presence on each channel It displays the ADC reading continuously sr This will test solenoid channel pulsing with automatic detection of head The Impression Pot varies the solenoid channel pulse width Pressing CLR BWD will toggle the Solenoid Test On Line this is indicated by being lit Pressing and holding SET FWD and either or H the machine will start continuously simulating pulsing To exit this item press STOP tESt07 TEST STEPPER motor current limit and running the motor either continuously or cycling the motor on for 10 seconds and off for 1 second DP5 indicates the direction of the motor when lit it is in the forward direction pressing CLR B WD will turn it off indicating the motor direction will rotate backward The button SET FWD will put the light back on in the forward direction Pressing either SET FWD or CLR B WD will run the motor in that direction for one step continuously holding it will run the motor continuously at setup speed indicates whether the motor is on off line pressing H1 will toggle this light on or off indicates whether the
26. e previously viewed menu The functions of the rest of the buttons will be discussed later in this section Once you have plugged the machine in turn the on off switch to the on position The microprocessor does an internal system check and the above will flash on the screen 5 1 Running a Job The Idle Mode is displayed below From this menu you can change the motor speed modify your paper count and select your program In this menu you can also enter the Batch size PERF SHIELD RED PHOTOCELL GRN ON PERF SHIELD OPEN ON NO PAPER IMPRESSION 2 18 DISPLAY FUNCTIONS DISPLAY ssssss motor speed bar graph PGMxxx solenoid program in RAM paper count decrement motor speed 1 increment motor speed 1 decrement paper count aaa CLR gt clear paper count normally aaa BAT gt Enter Mode Set Batch Size when batch mode is enabled The lt lt lt gt gt gt will adjust the motor speed F1 will decrement the paper count F2 will clear the paper count but if it is already at 0 it will send you to the Batch mode SETUP will select a program and START will begin the job You will now be in the Run Mode When the machine is first turned on it defaults to Program 01 PGMO01 which is shown on the menu Pressing the START button will automatically begin Program 01 The main operating menu will change as the machine is running The Run Mode menu looks like this PERF SHIE
27. e through the regulator set between 40 50 psi adjust the pulse width value up or down to provide a well inked number which does not emboss a light paper weight 20 75 gsm bond The next head can be adjusted in this same manner Default setting for this is 15 0 on the pneumatic units The factory setting is set at 12 5 When finished press ACC to save the value to the EEPROM and you will go back to the Manufacturer Test Menu If you do not want to save the changes press ESC and you will go to MFR Test Menu or Stop will put you in the Test Set Menu 7 TEST STEPPER This Mode allows the user to run a Stepper Motor Test and to set the TEST STEPPER MAIN Maximum Motor Speed The Maximum Motor Speed is factory set and TEST EXIT SET should not be changed To TEST the Motor press the gt gt key The factory setting for the GW 8000 is 79 and the GW 12000 at 90 The number beside the PER is the Motor Period in microseconds by turning the Impression Control Dial for H2 the number will either increase or decrease the higher the number the slower the motor will go Beside the MOT V is the actual motor voltage when OFF the voltage will be around 0 To run the motor it must be Online as indicated when F is the toggle and ONL appears the machines voltage will now read around 150 V F2 will toggle the motor HIGH or Low Current Limit Each pressing of the lt lt or gt gt will move the motor one step
28. ee full days in our plant using this program to burn in the circuits and weed out any other assembly or miscellaneous problems allows for a single hit program by pressing SET FWD it will come on or go off This light is usually off allowing for a ten hit program DPO is always on indicating hits existing in the default program Pressing the CLR BWD will clear the simulated paper count 064 To exit this item press STOP tESt02 DISPLAY PHOTOCELL ADC This is a machine value for the photocell The value should be approximately 60 Making adjustment on the gray pot located on the PSTEP board can change this value This is the bigger board located on the non operator side of the machine The pot is located at the top midsection of the board beside the two four pin connectors x S 5 mw O To exit this item press STOP tESt03 DISPLAY VOLTAGES will be lower than the actual line voltage DIGS 3 will read the actual motor voltage when off line the voltage will read around 0 When H2 1s pressed DP3 will light up indicating that the machine is now on line at this point the numbers to the left of the dot will be the actual motor voltage and the number to the right is the actual input line voltage reading The motor voltage typically will be around 150V if the voltage is higher than 160V
29. ent function and will either assist in machine set up or in diagnosing a malfunction Each is detailed and explained below 01 TEST IDLE When selected 1 TEST IDLE will run the current machine program over and over without the need to load paper The motor will run stop start and the heads will fire simulating a standard run This is useful after replacing a component on the machine and testing its correct installation We run each machine for a minimum 48 hours in our plant using this program to burn in the circuits and to weed out any other assembly or miscellaneous problems 25 02 DISPLAY PCELL ADC PHOTOCELL ADC 03 EXIT 03 DISPLAY VOLTAGES LINE VOLTAGE 109 MOTOR VOLTAGE 0030FF 04 DISPLAY SW DATES ICPU REV V990511 PSTP REV V990528 05 SET LANGUAGE ENGLISH y 1 EXIT SE 06 TEST SOLENOIDS TEST SOLENOID LOW TEST EXIT SE PW1 15000 PW2 15000 The photocells in the 8000 12000 are of a reflective type The actual emitter collector are in one stock electronic component It is mounted on the leading edge of the main platen operator side underneath a grooved cutout Above the photocell is a shiny reflector that is in a fixed position Adjustment on the photocell is now done directly on the main PSTEP board The value should be between 55 65 This mode will display the line voltage and the actual motor voltage When the motor is not in operation the voltage will read approximately 0 th
30. es and diagnostics Using these the equipment can be customised to the customer s requirements and or tuned to local electrical conditions The most critical of these is the minimum solenoid pulse width Each customer location will offer a different incoming voltage This voltage variation can result in an incorrect range of impression control being available to the user While most other values will remain at factory defaults this value must be changed for each new machine location All settings are simple enough for the customer to be coached through via telephone Upon installation or in the event of a circuit exchange the Set Up routine must be followed to ensure proper set up 5 9 OVERVIEW Access to all settable parameters is available through the keyboard while in the main operating menu This is the menu displayed when the machine is first turned on If you are not at this point press ESC as often as required to return to the main operating menu When at this point to get into the Manufacturer Test Menu press 1 2 9 The display will read 01 TEST IDLE The test program is one of the 10 available options Each of the others is accessible by pressing the appropriate number at any time or pressing the lt lt or gt gt keys to scroll forward or backward through the options and then ACC to enter that option Leave any item by pressing ESC or STOP 5 10 INDIVIDUAL ITEMS Each of the available options provides a differ
31. ess the H2 button and this will clear the memory 4 4 Changing and Programming a Job 0185 DIG4 DIG3 DIG2 0161 DIGO Whenever you wish to change or program a job insert a piece of paper into the feed tray and press the SET FWD button The paper will go through the machine and stop in front of the photocell The DIG 5 will have P indicating you are in the program mode DP 5 will light up indicating the motor is on in the forward position DIG 1 0 will have 75 and DP 0 will light up indicating that a DPS DP4 DP2 hit exists in the program To clear the memory completely press the CLR BWD button while holding it down press the H2 button you will notice DP 0 will go off this indicates that the memory and all hits have been cancelled As a guide refer to the orientation of the LED digit segments DIG 5 0 and the Decimal point functions DP 5 0 in the picture DIG 5 Displays P for Program Set up DIG 4 Displays h only if a hit has been programmed at the current position DIG 3 DIG 0 Current paper position in steps from the paper leading edge In run mode they act as paper count DP 5 Indicates the motor direction On Forward DP 4 If it is on it indicates all 10 hit positions are used DP 3 No function DP 2 Solenoid 1 On indicates Head 1 will be fired at the current position DP 1 Solenoid 2 On indicates Head 2 will be fired at the current position DP 0 Indicates
32. functioning replace PSTP board LD9 Paper Photocell Status Indicator e This LED indicates the status of the Paper Photocell paper breaks refection to detector e If there is no paper under the photocell LD9 will be on e If there is paper under the photocell LD9 will be off e lf this LED does not change state when breaking the Paper Photocell then the possible causes are e Paper Photocell not plugged into J13 on PSTP board or Photocell cable broken e Photocell not aligned properly or photocell broken e Paper photocell circuitry not functioning replace PSTP board 33 010 PSTP Transmit Indicator e This LED is an indicator whenever the PSTP board communicates to the ICPU Display boards e When the PSTP transmits LD10 should flash for a short period of time e When the PSTP is not transmitting LD10 should be off lf this LED does not flash 4s after power up if it is always on then the possible causes are e SCI phone cable not plugged into J15 on PSTP board and J1 on ICPU board e SCI phone cable made incorrectly or broken e Incorrect SW version for PSTP 3K SW not compatible with ICPU board e PSTP transmit circuitry not working error message should be displayed replace PSTP board LD11 PSTP Receive Indicator e This LED is an indicator whenever the ICPU Display boards communicate to the PSTP board e When the ICPU transmits LD10 should flash for a short period of time e When the ICPU is not transmitting LD10 sho
33. hes that have been completed of Batch Size DISPLAY PERF SHIELD RED PHOTOCELL GRN ON PERF SHIELD OPEN ON PAPER IMPRESSION 1 IMPRESSION 2 NO FUNCTION DISPLAY FUNCTIONS DISPLA Y XXXXX batch quantity EXIT exit to Mode Idle clear batch quantity This screen will show you how many batches you have completed Multiply the BATCH QTY by the BATCH SIZE and you have the total quantity of your run When the machine stops after each batch has been completed you may insert a slip sheet in the exit tray and simply press the START button to continue with the next set 5 6 The Repeat Function The repeat function key REP is a future feature for the GW 8 12000 Currently the repeat selector on the numbering head is used to obtain a repeat ability 5 7 Motor Speed Control The motor speed can be changed while the machine is running or idle This function is performed by using the first two function keys under the LCD display screen marked lt lt and gt gt when you are in the main operating menu The bottom line of the LCD display shows a down arrow to slow down the motor and an up arrow to speed it up Maximum throughput speed is 8 000 GW 8000 and 12 000 GW 12 000 sheets per hour 11 x 82 or A4 with one number per page 24 5 8 GW 8 12000 SOFTWARE SET UP amp DIAGNOSTICS DOE On both models the software offers a number of technician settable featur
34. is 15 represented by the OFF beside the number Pressing F2 will bring the motor online ONL While online the typical voltage will be about 150 If the reading is above 160 there is a problem The software versions on the ICPU and MSTP Board are displayed There is a choice of five languages to choose from ENGLISH SPANISH GERMAN PORTUGESE and FRENCH Use the lt lt or gt gt buttons to scroll through the different languages when you select the one press 2 or ACC In this mode you can test or set the minimum solenoid pulse width The test mode allows you to check the functionality of the low voltage solenoid board Once gt gt is pressed you are in the test mode PW stands for Pulse Width for Head 1 PW2 for H2 The values beside them are the Pule Widths in nano seconds They vary when the Impression Control Dials are turned With the dials completely counter cockwise it will display the minimum solenoid pulse width With the heads plugged in FT will fire H1 each time it is pressed F2 will fire H2 also each time it is pressed To obtain a continuous pulse press the lt lt key To set the 26 minimum solenoid pulse widths press STOP and then F2 The block beside the number indicates which head is currently being fired E mPW1 15 0 by selecting F1 or F2 The keys lt lt and gt gt increase or decrease the pulse mPW2 15 0 width With the air pressur
35. ive Components 8 9 GW 12000 Structural Parts Diagram 8 10 GW 3 6 8000 Shaft Placement 8 11 Conveyor Outfeed Assembly NO 00 00 00 ON DO Ur UY TECHNICAL HIGHLIGHTS Many of the benefits of our product design construction and materials details are not indicated in our product literature Obviously these details are important facts which are critical to a full understanding of our equipment We build what we feel is the best equipment available We take great pride and satisfaction in the knowledge that we offer true value and performance to every customer Our users consistently comment on the durability ease of use and versatility of their machines Their positive reactions are no accident Listed below are the reasons lt Feed System we use a feed system on all our automatic machines unlike any other The stock is fanned forward so that the lead sheet only touches the feed tires There is a complete lead edge retarding strip that will hold back following sheets We use three feed tires evenly spaced along the lead edge the two outside tires 12 from the edge of the stock and the third in the middle of the page for a more consistent straight paper feed The pressure of the feed tires needs only be enough that you feel a slight resistance between the stock and feed tires This feed system provides consistent feeding with drastically less problems of skewing kicking marking scuffing and double feeding of your stock lt Head D
36. lenoid error occurs at power up then the most likely cause is e Incorrect solenoid board attached to PSTP board e Incorrect ICPU Display SW 35 e This error cannot be cleared by keypress the fault must be fixed in order to clear the error EEPROM Errors e Ifan EEP error occurs at power up then the most likely cause is e Switching PSTP boards without reformatting the CPU EEPROM e Faulty EEPROM on ICPU If encounter EEP errors at power up e Press STOP or ESC until all EEP errors are cleared e Format EEP e Power the machine down e Power up the machine again e If still encounter EEP errors replace ICPU board SCI Errors e If SCI errors occur at power up they cannot be cleared by a keypress the fault must be fixed in order to clear the error e To clear fault isolate the problem refer to section above for PSTP transmit and receive LEDs e Error could also be caused by SW mismatches verify that PSTP SW is compatible with ICPU SW RAM Errors 6K 8K and 12K only If this error occurs at power up this error is display by flashing the Photocell LED on the display boards e If RAM errors occur at power up they cannot be cleared by a keypress the fault must be fixed in order to clear the error e The probable cause of the problem is a faulty RAM chip replace ICPU board Errors Encountered when Running Programs Paper Errors e Generally paper errors can be cleared by hitting STOP or ESC e The error message displayed
37. ly working on move the next stock into the starting position and then stop the motor 2 If you want to stop the machine while stock is still left in it simply hold on to the stock in the feed tray After about one second the machine will automatically stop since it is no longer seeing any new sheets This is how it also stops when all of the stock in the feed tray is gone 3 Pressing any of the other buttons will stop the machine defaulting the machine to its idle mode 8 3 3 Clearing Job To completely clear a program from the memory insert a paper in the feed tray Press the SET FWD button The paper will then feed through and stop at 75 Press the CLR BWD button and hold it down next press the H2 button and this will clear the memory of the previous job You can now run just a perf score slit job by pressing START 3 4 Changing and Programming a Job The following describes Mode Program Setup operation Loads a new sheet of paper regardless if paper is already in the machine or not Paper is loaded into the machine at Setup Paper Speed and stops at Paper Position Stop Motor advances in single steps or continuously at Setup Paper Speed using the lt FWD gt and lt BWD gt keys The motor stops when the key is released Motor operation will stop while holding down either of the lt FWD gt and lt BWD gt keys once the existing programmed hit location is reached Another key down lt FWD gt or lt BWD gt
38. must be detected before moving off of the hit position Heads fire according to the current program i e when the sheet reaches the hit position or when the lt H1 gt and or lt H2 gt key is pressed lt H2 gt can only be fired once lt H1 gt is programmed at the same hit location lt H1 gt must be fired first followed by H2 Pressing H2 without having first programmed H1 does nothing If H1 H2 is pressed at a current hit position the head to fire will be toggled ON OFF Pressing H1 toggles ON OFF SOLI pressing H2 toggles ON OFF SOL2 when SOL 15 programmed If H1 and H2 are both programmed at the hit position and H1 is removed the H2 hit data is automatically removed from the solenoid program If a solenoid head error is reported hit data may still be programmed and saved Creation of hit data can be performed at any paper position If the solenoid is fired at a new position followed by pressing the START key any existing old hit data will be overwritten and the new position and hit data saved When the START key is pressed the changes to the program are saved to the EEPROM the current sheet is ejected and the next sheet is loaded to Paper Position Stop If the STOP key is pressed any changes made during Setup are aborted and the solenoid program will be re loaded from EEPROM The exception is if a EEPROM error exists then the solenoid program workspace in RAM will
39. n 3 x5 7 6 x 12 7 cm Electrical configuration Voltage 90 135 VAC or 180 270 VAC Frequency 60 Hz or 50 Hz Fusing 115 250V On the Circuit Board refer to diagram there is a 6 Pin Main Connector male Numbering the 2 0 GW JUNIOR MODULAR SWITCH W FUSEHOLDER 90 062 GW BLUE SOLENOIDS FOOTPEDAL 6 Pin Connector 20 013 GW 25 012 GW 2 Pin Impression Impression Control Control Connector Potentiometer harness 20 015 GW Model J 1 Circuit Board 2 1 GW Junior Circuit Board Values pins as follows 6 5 4 3 2 1 from the wires you will have the following values 1 amp 6 283 485 Power you should then read the line voltage to the circuit VAC Footpedal by pressing the footpedal you will see the resistance change as the line opens and closes Solenoid the solenoid resistance value will be approximately 400 ohms On older machines this value may range from 40 to 900 6 2 2 Troubleshooting If you do not have a line voltage reading from pins 1 amp 6 there is a break in the line and repairs are required First check the main fuse then trace back the line for breaks If there is no resistance reading from the Solenoid replacement is required of both the Solenoid and Circuit Board Once the Solenoid shorts the Circuit Board will then have a short somewhere on the real estate If there is no reading variation from the Footpedal check the line for breaks There
40. not in J5 or incorrect jumper in J5 black for 110VAC purple for 220VAC e X1 or not functioning or short on P 12V line replace PSTP board LD6 Primary 5V Supply Indicator e This LED indicates whether the primary 5 supply is alive e fthis LED is not on then the possible causes are Machine not turned on e AC power connector not plugged into J2 PSTP board or cable broken e Jumper not in J5 or incorrect jumper in J5 black for 110VAC purple for 220VAC e X1 VR3 or VR4 not functioning or short on P 5V line replace PSTP board LD7 Perf Status Indicator e This LED indicates the status of the Perf fthe Perf is closed LD7 will be on e If the Perf is open LD7 will be off e lf this LED does not change state when opening closing the Perf shield then the possible causes are Perf cable not plugged into J11 on PSTP board or Perf cable broken e Perf switch broken Perf circuitry not functioning replace PSTP board LD8 Start Photocell Status Indicator e This LED indicates the status of the Start Photocell paper reflects to detector e If there is no paper under the photocell LD8 will be off e If there is paper under the photocell LD8 will be on e lf this LED does not change state when breaking the Start Photocell then the possible causes are e Start Photocell not plugged into J12 on PSTP board or Photocell cable broken e Photocell not aligned properly or photocell broken e Start photocell circuitry not
41. o exit out of this mode press and hold down the H and then the STOP tESt010 TEST FORMAT EEPROM This tests and formats the EEPROM sections that are used by loading the programmable parameter defaults into the EEPROM and RAM It will also write an empty solenoid program into the memory Pressing the CLR BWD will commence erasing the EEPROM DP4 will turn on senile the Test Format is in progress Notice once the formatting is initiated it cannot be aborted To exit this item press STOP E E E 5 16 4 9 GW 6000 Error Codes __________________ 05 _______ MSTPPAPER ERROR REPORTED IS UNDEFINED O Z O Z OZ Solenoid Errors 14 CH2 SHORT ___ 18 _______ NOSOLENOID BOARD ATTACHED ___ 8 LOW VOLTAGE SOLENOID BOARD ATTACHED SOLENOID TIMEOUT 7 8 9 0 SOLENOIDTIMEOUT ff O Motor Errors 0 1 32 39 Reserved 0 1 2 3 4 5 EEPROM Errors UNABLE TO READ FROM EEPROM o 40 41 UNABLETOWRITETOEEROM CRC INVALID FOR EEPROM PROGRAMMABLE PARAMETERS CHECKSUM INVALID FOR EEPROM SOLENOID PROGRAM 4 TESTING FAILED DURING TEST RE FORMATEEPROM 45 EEPROM VERSION FORMAT DOES NOTMATCHSOFTWARE RAM SELF TEST READ WRITE FAILURE CHECKSUM INVALID FOR RAM SOLENOID PROGRAM 50 CRC INVALID FOR RAM PROGR
42. oblem and allow full details to the technician by phone The problem is immediately identified and correction can be carried out without requiring a service call Exchanging the circuit boards has also been made simple enough that a technician may not be required Of course with our network of dealers across the country help is never more than a phone call away lt Drive Train all drive components are metal The main timing belt is steel reinforced The motors are brushless All require no maintenance This listing could continue and provide you with every little detail we ve sweated over while designing and building your machine We can and will if you ask tell you about gold plated contacts idc type connectors and a host of other things It s your right to know that you are getting your money s worth Our final word here is to tell you what we don t do Quite simply we don t add cosmetic features which have no effect on performance and add only to cost We don t stand still and we continue to evolve the products based on experience and field comments We redesign with our existing customers in mind and make all future enhancements retrofitable to the first machine we built We don t run down our competitors and their products we strive to stay a few steps ahead of them We know that if you really look you will recognize the value in our products We sincerely appreciate your interest and your time reading through this note Please contac
43. ply on the LVS board is alive e lf this LED is not on then the possible causes e LVS cable not plugged into J15 on LVS board and J8 on PSTP board e LVS cable broken or not made correctly e Short on the S 12V line replace LVS board ICPU Display Boards The probable causes for ICPU faults assume that there are no problems with the PSTP board e All of the problems listed above for the PSTP board are not present LD1 Secondary 5V Supply Indicator e This LED indicates whether the secondary 5V supply on the ICPU is alive e lf this LED is not on then the possible causes e SCI phone cable not plugged into J15 on PSTP board and J1 on ICPU board e SCI phone cable made incorrectly or broken e not functioning or short on S 5V line replace ICPU board 3K Keypad The probable causes for LVS faults assume that there are no problems with the PSTP board e All of the problems listed above for the PSTP board are not present If Perf and Photocell LEDs do not change state when open close perf and break Pcell then the possible causes are e SCI phone cable not plugged into J15 on PSTP board and J1 on KPAD board e SCI phone cable made incorrectly or broken e KPAD board not functioning replace board Error Messages Errors At Power up Solenoid Errors If this error occurs the machine should be powered down and then power back up again to verify that the error occurs at least two consecutive times e Ifa so
44. rgy output and optimum efficiency The moving plunger is coated with molybdenum disulphide an anti friction coating used in jet airplane engines Numbering Head the standard numbering head offered is an all steel numbering machine manufactured by Reiner Gmbh amp Co in Germany It has been our head of choice since the beginnings of our machine design ten years ago and has proved so reliable that two of our competitors subsequently chose the same supplier s numbering head for use in their machines Drive Unit Mount Assembly thick stiff and durable The first of our many never replaced due to a failure parts Shafting all the turning shafting in our products is made from a special high tensile strength steel which offers the strength rigidity resistance to deflection and a number of other critical mechanical properties normally available only on shafting of significantly larger diameter The shafting is supplied centerless ground to exacting specifications measured at one half of one thousandth of an inch 0 0005 Once machined to its final dimensions We straighten the shafting to within one thousandth over its length to ensure consistency and accuracy in perforating scoring or slitting operations The shafting is also plated with a very hard skin of chromium to prevent corrosion and marking from setscrews This shafting has proved so durable that we have never replaced a shaft on any unit due to wear or fatigue
45. river we are unique in the way we propel our numbering heads to the paper We refer to it as inertia drive Whether using our solenoid or pneumatic drivers there is no direct coupling of the numbering head and the driver The driver stroke is shorter than the head s travel to the paper The driver has been specifically engineered to produce rapid acceleration impact the numbering head under inertia and immediately release With the inertia from the driver the numbering head is propelled to the paper makes an impression on the paper and is free to return after hitting the platen The result is a clean and clear number Think of it as throwing a ball against the wall and having it bounce back rather than pushing the ball into the wall The further benefit to this method is the reduced wear and tear on the head frame components wheels etc Resulting in longer head life Electronic Impression Control microprocessor and digital control in all our models allow us to control with great precision the time for which we energize our drive This allows us to impart more or less inertia to the head depending on how much of the stroke we energize for thus controlling the strength of our numbering head crash Simply put the longer we accelerate for the faster we go the harder we hit Solenoid Design just look at one The totally enclosed tubular design creates the most efficient complete magnetic flux path providing the maximum ene
46. ructed to INSERT PAPER PRESS START The LCD display will return to Idle Mode and you are set to run the job Simply press the START button to begin 22 5 5 The Batch Function Pressing the BAT key before running a program will enter the batch menu FUNCTION 1 Allows user to set or clear the batch size max batch size 999999 2 Sets a new batch size by pressing lt ACC gt The paper count and batch quantity are reset to 0 DISPLAY PERF SHIELD RED PHOTOCELL GRN IMPRESSION 1 Q ON PERF SHIELD OPEN ON NO PAPER NO FUNCTION IMPRESSION 2 NO FUNCTION DISPLAY FUNCTIONS DISPLAY XXXXX batch size SET sets the batch size CLR sets the batch size to zero At this point you may select the size of the batch desired by entering the desired batch size through the keypad Press key when the quantity desired has been chosen Press the F2 key CLR if you wish to clear a quantity entered to disengage the batch function Once again the ESC key will return you back to the main operating menu without activating the batch function Pressing F1 will reset the paper count and batch quantity 23 When running job with the batch function the machine will stop after the last sheet has been processed leaving the sheet partially in the exit rollers allowing you to insert a slipsheet The LCD display will then show the number of batches completed FUNCTION 1 Displays the number of batc
47. sheet back further than position 75 The other two function keys fire either head 1 or head 2 Once a head fire button has been pressed the numbering head will fire and the LCD display will light up with one solid bar around the corresponding head fired eg BC1 In a four head system heads 1 amp 3 work together and heads 2 amp 4 respectively To activate heads 1 amp 3 at any position press F1 head 1 will fire and will appear on the display press 3 on the keypad and head 3 will fire and C13 will appear To activate head 2 amp 4 you must press the number 2 and 4 on the keypad and 24 will appear on your display Configured we can have in any one program with a four head machine a combination of at any one time heads 1 amp 2 amp 3 amp 4 1 amp 3 2 amp 4 1 2 Heads 3 amp 4 cannot activate on their own If the number is not in the position desired simply press the function button again to toggle off the hit otherwise continue moving up or down the sheet the hit is automatically saved This procedure can be repeated until the number is in the correct location The page can be stopped a maximum of 15 times where you may program head 1 or head 2 or both heads to fire Once all numbers desired have been programmed simply press the button and the sheet will be discharged from the machine The next sheet will be forwarded to step 75 if there is another sheet already in the feed tray or you will be inst
48. should be looked up in error messages table to identify the cause of the problem in order to fix it Solenoid Errors e Generally solenoid errors can be cleared by hitting STOP or ESC e The error message displayed should be looked up in error messages table to identify the cause of the problem in order to fix it SCI Errors e Generally SCI errors can be cleared by hitting STOP or ESC 36 e Ifthe error message keeps recurring then there is probably a fault with either the hardware software e Power down the machine and then power up again e If get SCI errors then to clear fault isolate the problem refer to section above for PSTP transmit and receive LEDs e Motor Errors e Generally motor errors can be cleared by hitting STOP or ESC e Ifthe error message keeps recurring then there is probably a fault with the hardware replace PSTP board 3K Error Messages e Error messages for the 3K are displayed on the perf and photocell LEDs e Observe when the Perf LED red flashes e Count how many times the Photocell LED green flashes until the Perf LED flashes again e The number of times the Photocell LED flashes corresponds to the error see error message table for 3K e Errors At Power up e EEPROM Errors If an EEP error occurs at power up then the most likely cause is e Not formatting PSTP EEPROM e Faulty EEPROM on PSTP e If encounter EEP errors at power up e Press STOP PSTP should automatically reformat EEPROM e Power
49. t Bock opse 60005 GW X Bhat Pie Tray Mount Block nonopsde 60 006 GW X X Pile Tray 7 6554 K Conveyar Actuator Frame 60008 GW a 60 011 GW X X Conveyor Spur Gear K GeweerTepRobrSupotAm mowsaw K K Conveyor Top RollerSha K X Conveyor Top Foley 651554 _ K pK Gmel 64794 EK GmwewrSetSpo K K Fese roman K K 7 554 X lt Operator Side Smal over K mowraw K edPMeyweurger _ roman K K reed Rule posan K K 40 PART JR 3K 6K 8K DESCRIPTION 100 m 0594 L L oson P e i ponema 80 006 GW X Timing Belt 140XL037 33 80 007 GW X X X Controller AO Exchange mese X 85007 GW X K Controller 230 VAC Exchange C L L F X X X X CEET Pate 654 K K KD Non Operator Sie Cover waar Orato Se Cover x K K K Motor Fete Bead K K KK K K
50. t the requirements of the job For example you may require stronger crash numbering for carbonless sets than for single sheet bond paper This adjustment can be done while the machine is stopped or running The four buttons under the LED display will perform whatever function is shown directly on them SET FWD Is used to set up a numbering job and incrementing the motor in a forward direction CLR B WD Is used to clear programs and increment the motor backwards 1 Is used to control head number one which is the head closest to the operator H2 Is used to control head number two which is the head furthest away from the operator START Is used to start the machine STOP Is used to stop the machine Once you have plugged the machine in turn the on off switch to the position The LEDs will flicker and then stop The GW 3000 does systematic error checks if it detects an error the LEDs will remain flickering count the number of flickers and compare with the list of all possible error codes 3 1 Running a Job The machine is capable of storing a 1 job 1 hit for recall and future use Ensure that there is paper in the feed tray first Pressing the START button will automatically begin the program that was previously programmed in the memory 3 2 Stopping a Job There are two methods of stopping the machine 1 Once the program is running pressing the STOP button will cause the machine to finish the stock it is current
51. t your local dealer or us if you require any further details 1 0 SPECIFICATIONS GW Junior Tabletop footpedal operated numbering machine standard forward head GW 3000 Programmable for a single hit per sheet per head auto feed numbering perforating scoring system single speed of 3000 sheets per hour maximum of two numbering heads optional conveyor outfeed and stand GW 6000 Programmable for up to 10 hits per sheet per head auto feed numbering perforating scoring system three speeds of up to 6000 sheets per hour maximum of two numbering heads optional conveyor outfeed and stand GW 8000 Programmable 100 job memory for up to 100 hits per sheet per head auto feed numbering perforating scoring system batching capability variable speeds of up to 8000 sheets per hour maximum of four pneumatic numbering heads optional conveyor outfeed GW 12000 Programmable 100 job memory for up to 100 hits per sheet per head auto feed numbering perforating scoring system batching capability variable speeds of up to 12000 sheets per hour maximum of four pneumatic numbering heads conveyor outfeed optional air feed FinishMaster 100 Table top autofeed perf score slit system up to 10 000 sheets per hour optional conveyor outfeed and stand FinishMaster 150 Autofeed perf score slit system up to 20 000 sheets per hour optional air feed Paper weight 12 12 point 45 250 gsm Paper formats max 18 x 18 45 x 45 cm mi
52. the motor This automatically sends you into Idle Mode 2 If you want to stop the machine while stock is still left in it simply hold on to the stock in the feed tray After about one second the machine will automatically stop since it is no longer seeing any new sheets This is how it also stops when all of the stock in the feed tray is gone 5 3 Changing Programs The GW 8 12000 allows you several choices in programming PROGRAM 00 Perf score automatically turns the numbering heads off PROGRAM 01 99 Allows for a maximum of 10 hits per head PROGRAM 100 Allows for a maximum of 100 hits per head Whenever you wish to change programs the LCD display must be in Idle Mode press the SET UP button The following screen will appear DISPLAY PERF SHIELD RED PHOTOCELL GRN IMPRESSION 1 Q ON PERF SHIELD OPEN ON NO PAPER NO FUNCTION IMPRESSION 2 NO FUNCTION 20 Once you select the program number desired you may either RUN the existing program or EDIT it by pressing the corresponding function key F1 to RUN amp F2 to EDIT If RUN is selected the machine will exit to Idle Mode where you press START The ESC key will also return to Idle Mode in case you wish to change the counter before beginning a job 5 4 Programming a Job If you wish to program a job EDIT an existing program press F2 After selecting EDIT if the program already exists the machine will ask whether you would like to erase it
53. then there is a problem In 220 volt systems the line voltage will be approximately half of the actual line input voltage EE This displays the motor off line DIG2 0 will display the line voltage it To exit this item press STOP tESt04 DISPLAY SOFTWARE VERSION l TL Tl This mode will indicate the software version dates of the ICPU software and the MSTP software Default on entry is the ICPU Software Version _ indicated by Pressing H will display the MSTP version in which the will disappear H1 will get you back to the ICPU version To exit this item press STOP 14 tESt05 SET SOLENOID MINIMUM PULSE WIDTH ent ee EE This will display and modify Channel 1 and or Channel 2 minimum ul l ll I pulse width parameters The Minimum Pulse Width value is 10 msec Il I 1 0 l 1 1 and the maximum is 20 msec Default is set at 15 msec It is factory set at 13 5 is a decimal point indicates that Channel 1 has been selected DP1 is a decimal point will indicate when Channel 2 has been selected DIGS 3 are the values for Channel 1 and DIG2 0 are for Channel 2 The SET FWD increments and the CLR BWD decrements these buttons will vary the value by 0 1 msec increments when pushed holding down will fast increment the numbers Pressing Stop will a
54. uld be off e lf this LED does not flash 4s after power up or if it is always on then the possible causes are e SCI phone cable not plugged into J15 on PSTP board and J1 on ICPU board SCI phone cable made incorrectly or broken e Incorrect SW version for PSTP 3K SW not compatible with ICPU board PSTP receive circuitry not working error message should be displayed replace PSTP board NOTE for the 3K machine LD10 should always be on and LD11 should flash dimly when keys are pressed on the KPAD High Voltage Solenoid Board The probable causes for HVS faults assume that there are no problems with the PSTP board All of the problems listed above for the PSTP board are not present LD1 Primary 12V Supply Indicator e This LED indicates whether the primary 12V logic supply on the HVS board is alive lf this LED is not on then the possible causes are e Short on the P 12V line or R48 opened replace HVS board Low Voltage Solenoid Board The probable causes for LVS faults assume that there are no problems with the PSTP board e All of the problems listed above for the PSTP board are not present LD8 Primary 12V Supply Indicator 34 This LED indicates whether the primary 12V logic supply on the LVS board is alive lf this LED is not on then the possible causes e Short on the P 12V line replace LVS board LD10 Secondary 12V Supply Indicator e This LED indicates whether the Secondary 12V logic sup
55. w 3 YELLOW BLACK FED RED HV SOLENOID TO MSTP BOARD POWER CABLE 90 068 GW FILTER TO MSTP BOARD CABLE 90 064 GW 6 1 GW 3 6000 CIRCUIT 6K ICPU EPROM 92 027 GW 6K LED ICPU DISPLAY BOARD BACK 92 029 GW X 3K 90 029 GW MODULAR SWITCH WIFUSEHOLDER 90 062 GW aue it nd 6K LEDICPU DISPLAY BOARD c BLUE FRONT I I 92 029 GW X seca ADO El of 90 029 GW w 040 E es E aa BROWN SAFETY SWITCH WIHARNESS 50016647 PHOTOCELL ASSEMBLY 90 067 GW PHOTOCELL VOLTAGE POTENTIOMETER TELEPHONE CABLE 90 030 GW 3 53885 e oo 3 S 6K MSTP EPROM 92 026 GW a EPROM 90 026 GW 3K MSTP BOARD 90 025 GW X 6K BOARD 92 025 GW X 120 V 220 V STEPPER MOTOR MSTP BOARD MSTP BOARD Piden CONNECTOR CONNECTOR 90 060 GW 90 061 GW 30 BLUE eem BROWN d LINE FILTER 90 063 GW HV SOLENOID TO MSTP BOARD POWER CABLE 6 2 GW 8 12000 CIRCUIT MODULAR SWITCH WIFUSEHOLDER 90 062 GW LED ICPU DISPLAY BOARD BACK 94 029 GW 94 029 GW X ICPU EPROM 94 027 GW LED ICPU DISPLAY PO B 90 083 GW LOW VOLTAGE SOLENOID BOARD 94 028 GW 94 028 GW X LO

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