Beruflich Dokumente
Kultur Dokumente
Service Manual
SEPTEMBER 1995
Part # 90420
Contents T08014 TJ
PAGE
REP 2.4 Feed motor assembly MOT 1-10 2.4.1 SEPTEMBER -95
PROGRAMMING ( PRG )
PRG 3.1 Reset and restoring of EE-prom values 3.1.1 - 6 SEPTEMBER -95
EDI 4.7 PCB layout Main circuit board 90 - 1 4.7.1 SEPTEMBER -95
EDI 4.8 PCB layout Power supply circuit board 90 - 2 4.8.1 SEPTEMBER -95
MAINTENANCE ( MTN )
MTN 6.1 High frequency parts maintenance table 6.1.1 SEPTEMBER -95
In order to facilitate the service of the Models 300/400 Collators there are a few special
tools available.
REMOVAL
Front cover.
1. Switch off the main power switch and disconnect the power cord.
2. Remove all sheet metal screws holding the front cover 1 to the side frame.
3. Lift off the cover.
Rear cover.
1. Switch off the main power switch and disconnect the power cord.
2. Loosen the two screws 2 with a 10 mm wrench.
3. Pull out the rear cover 3 in the lower end and pull down to release the cover.
INSTALLATION
NOTE: Avoid direct light on the Slotted Optical Switches ( SOS ) on rear side of the
machine if operating with the covers off.
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove front cover according to CRI 1.1
3. Disconnect the ribbon cable 1.
4. Disconnect the two connectors 2.
5. Remove the four counter sunk screws 3 and remove the front panel assembly.
6. Remove the four spacer pins 4 and lift off the circuit board.
3(x4)
4 (x4)
DIP
SWITCHES
1
1 2
3
4
5
6
7
8
9
10
1
2
3
4
5
INSTALLATION / ADJUSTMENT
1. Installation is an exact reversed procedure of removal.
CAUTION: Always handle the main circuit board and micro processor in accordance with
electrostatic discharges procedures ( ESD ). The circuit board contains components that are
sensitive to ESD damage.
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove front cover according to CRI 1.1
3. Remove front panel according to REP2.1
4. There are two slots in the corner of the microprocessor socket 1 that should be used
when removing the microprocessor.
5. When removing, use an extractor tool for PLCC 84 chip carrier.
B 1
A
VXX
Micro processor
888
INSTALLATION / ADJUSTMENT
1. When installing the microprocessor make sure that the notch A corresponds with the
arrow B in the socket.
2. Apply an even pressure on the microprocessor until it is fully inserted.
3. Mount the front panel.
4. Make a reset of the EE-prom and reprogram according to PRG 3.1
5. Mount the front cover.
CAUTION: Always handle the main circuit board and micro processor in accordance with
electrostatic discharges procedures ( ESD ). The circuit board contains components that are
sensitive to ESD damage.
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove rear cover according to CRI 1.1
3. Disconnect the three connectors J4, J5 and J6.
4. Remove the four nuts 1.
5. Move the wire harness to the side, pull out the circuit board.
Yellow
11
10
9
8
7
6
1 (x4)
J5 5
TR1 4
3
2
1
J6
1234 5
4
J4 3
2
Yellow
1
Red
INSTALLATION / ADJUSTMENT
1. Mount the circuit board with the four nuts 1.
2. Connect all three connectors, colours corresponding with drawing.
3. Connect the power cord and switch on the machine.
4. Check/adjust voltage to feed motors between pin 3 at connector J4 and a black common
ground. Adjust on potentiometer TR1 to obtain 23 + / - 0.1 VDC.
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove rear cover according to CRI 1.1
3. Remove feed roller assy from bin.
4. Remove bin extension plate from bin.
5. Unsolder the wires from the motor on rear side of machine.
6. Remove the three allen screws 1 that hold the motor to the side frame.
7. Lift out the motor from rear side.
1 (x3)
INSTALLATION / ADJUSTMENT
1. Mount the motor with the three screws 1.
2. Solder the wires to the motor, black wires to minus (-).
3. Mount the feed roller assy and bin extension plate.
4. Mount the rear cover.
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove front and rear cover according to CRI 1.1.
3. Remove the two counter sunk screws 1 and the two screws 2 holding the side guide 3.
4. Remove the side guide 3 and the stacker plate 4.
5. Remove one of the nuts holding the ground strap 5.
6. Remove the screws holding the shaft 6 to the side frame.
7. Remove the screw holding the linkage for stacker movement 7 and remove the stacker
bracket assembly.
7. Remove the two self tapping screws 8 holding the plate 9 from underneath the machine
and lift out the plate.
A3 A4 A5
1
0
REMOVAL
8. Loosen the screw holding the idler shaft 10 to achieve some slack in the drive chain 11.
9. Remove the screws holding the slotted optical switch 12 and lift off the switch from code
disc 13.
10. Remove the code disc 13 and the sprocket 14.
11. Remove the three screws 15 holding the motor and lift out the motor from
the right side.
5 - 15 mm.
11
12
10
15
13
14
YELLOW BLACK
BLACK VIOLET
INSTALLATION
1. When installing make sure that the slotted optical switch 12 does not hit the code disc 13.
2. Tension the drive chain with the idler shaft 10 until a slack between 5 - 15mm is
obtained at the point indicated by arrows.
REMOVAL
1. Open the conveyor belt door assembly. Remove the cover 1 by removing the nuts and
washers 2.
2. Remove the screws holding the tension shaft 3.
3. Remove the O-rings 4 from the idler shaft 5 and lift out the shaft.
4. Remove the drive shaft 6 by removing the retaining rings 7 holding the bearings in position.
Push the bearings towards the middle of the shaft and remove the shaft.
5. Remove all the retaining rings and springs on one side of the pressure rollers 8 and push
the rollers to the other side.
6. Remove the screws holding the supporter shaft 9 and remove the shafts.
7. Remove the conveyor belt by sliding it out between the pressure rollers and the paper path.
3 8
9
7
4 5
INSTALLATION
Installation is an exact reversed procedure of removal.
NOTE: When belt is tensioned, make sure that the belt is centered on the idler roller and tension
roller.
ADJUSTMENT
1. Remove front and rear cover according to CRI 1.1
2. Open the conveyor belt door.
3. Place a ruler on top of the shunt plate and slide it towards the operator side frame.
4. Loosen the screws holding the shunt plate pins 1 to the side frames.
5. Move the shunt plate up / down until the ruler is in the middle of the hole in the side frame.
Follow with the opposite side until the distance X is equal on both sides.
Hole in side frame Ruler
Shunt plate
X X
Ruler
7-9 mm
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove Rear cover according to CRI 1.1.
3. Remove the five screws holding the Transmission support plate 1.
4. Remove the two screws holding the Shunt solenoid bracket 2 to chassis and separate
solenoid from Plunger.
5. Loosen Roller assembly 3 two revolutions and remove the upper chain 4.
6. Pull the Reversing sprockets 5 off the Shaft extensions 6.
7. Loosen the Roller assembly 7 two revolutions and remove the lower chain 8.
8. Remove the Inner sprockets by loosening the two set screws in each sprocket and pull them
off the Shaft extensions.
9. Remove the Shaft extensions 6 from the Outfeed shafts by loosening the set screw in each
extension.
5-10 mm
4
3
1
5-10 mm
6
7
5
9 8
INSTALLATION / ADJUSTMENT
1. Mount the Shaft extensions 6 onto the Outfeed shafts.
2. Mount the Inner sprockets onto the Shaft extensions positioned with the teeth on the
sprocket 24-26 mm from the chassis (aligned with sprocket on motor).
3. Place one washer on each shaft and mount the Reversing sprockets positioned with the
teeth towards the side frame.
4. Route the lower chain 8 (thick line) according to the drawing above and tension the Roller
assembly 7 until it is possible to move the lower chain 5-10 mm up and down according to
drawing above.
5. Route the upper chain 4 according to the drawing above and tension the Roller
assembly 3 until it is possible to move the upper chain 5-10 mm up and down according to
drawing above.
6. If the connectors to Sensor 9 have been removed, connect wires acc. to drawing below.
7. Fit the Plunger into the Shunt solenoid, mount the Shunt solenoid bracket and adjust the
Solenoid position according to REP 2.7. YELLOW BLACK
8. Mount the Rear cover. BLACK VIOLET
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove front and rear cover on the 310B collator according to CRI 1.1.
3. Remove the tension shaft assy. 1 by removing the screws 2.
4. Remove the cover 3 by removing the nuts and screws 4.
5. Remove the supporter 5 by removing the nuts 6.
6. Remove the cover 7 by removing the nuts 8.
7. Remove the extension plate 9 by removing the nuts 10.
3 4
5 6
7 8 9 10
REMOVAL
8. Loosen the screw holding the idler shafts 11 by turning the shafts.
9. Remove the five screws holding the transmission plate 12 and lift off the plate.
10.Lift off the drive chains from the sprockets at the shaft assy. 13.
11.Remove the shaft assy 13 by loosening the two set screws closest to the side frame on shaft.
12.Loosen the two screws 14 and remove the screw 15 holding the cover 16 to the side frame,
remove the cover.
13.Remove the two screws holding the transport chassis to the side frame ( screws not shown
in drawing ).
14.Slip the transport belt through the slot in the transport chassis to enable removing of
transport chassis.
15.Remove the retaining ring 17 and the flange bushing 18.
16.Slide the drive shaft 19 to the side and remove the transport belt.
12
11
13
19
18
15
17
14 16
INSTALLATION
1. Installation is an exact reversed procedure of removal.
NOTE: Tension the transport belt according to REP 2.6
Tension the drive chains according to REP 2.8
REMOVAL
1. Open the conveyor belt door.
2. Remove the four screws 1 and remove the plate 2. ( For easier access to the two inner
screws the cover for conveyor belt transport can be removed ).
3. Disconnect the phototransistor or LED ( below machine serial no. 90041143 on 10 station
Collators and 90044807 on 6 station Collators wires are soldered to phototransistor and
LED ).
4. Remove the LED by removing the nut 3.
5. Remove the phototransistor assy by removing the nut 4.
Bin LED
1
Bin Phototransistor
INSTALLATION / ADJUSTMENT
PURPOSE
The purpose is to align the phototransistor with the LED to obtain the correct setting for the
double sheet detector ( DSD ).
1. Connect Black wire to short leg (-) on LED.
2. Connect Violet wire to short leg (-) on phototransistor.
3. Remove front cover according to CRI 1.1.
4. Switch DIP switch 2 on front panel PCB to left position to display the double sheet
detection values ( DSD ), see EDI 4.3.
The value for each bin will show for one second while the corresponding bin LED is lit.
Push switch SW6 on front panel to display a particular value constantly, see PRG 3.1.
5. Insert a white non printed 80 gram paper between the phototransistor and the LED.
Move the phototransistor sideways to obtain a value of 250 + / - 15 on the display, tighten
the nut that holds the phototransistor.
6. Remove the sheet and check that the value is more than 500. If value is lower than 500
replace the phototransistor.
The lower LED 12 is only in use for a short period of time during the machine cycle when the
Corner stapler 91 is attached. This has to do with the fact that corner stapled sets will be thicker
in one corner. To prevent the sets from falling out from the stacker, the capacity is reduced by
using the lower LED 12 to illuminate the phototransistor.
REMOVAL
1. Remove front cover according to CRI 1.1.
2. Disconnect the LED’s.
3. Remove the LED bracket 1 by removing the two nuts 2.
4. Remove the LED’s by removing the nuts 3.
2
A3 A4 A5
3
1
0
INSTALLATION / ADJUSTMENT
PURPOSE
The purpose is to initiate the EE prom reset process in response to minor logic problems, such
as failure in the operating sequence. The procedure also includes restoring of original values.
PROCEDURE
1. Remove front cover according to CRI 1.1
2. Switch off main power switch.
3. Reset the EE prom by sliding DIP switch no.3 to right position.
4. Switch on the main power switch, wait app. 5 seconds until ”HEL” appears on the display.
The values in the EE prom is now erased.
5. Switch off the main power switch and slide DIP switch no. 3 back to left position.
6. Switch on the main power switch. The Micro processor will now load the EE prom with
the original values. Always make sure that the correct values are entered in the EE prom
by entering the program mode and verify the settings according to label on machine side
frame.
1
2
3
4
5
6
7 DIP SWITCHES
8
9
10
1
2
3
4
5
CAUTION: Always handle the main circuit board and micro processor in accordance with
electrostatic discharges procedures ( ESD ). The circuit board contains components that are
sensitive to ESD damage.
PURPOSE
There are two mode switches SW6 and SW9 on the front panel for service use only, they are
located directly under the calibration button SW5 and the start / stop button SW8.
SW6 will display the total number of machine cycles shown in kilo cycles, display by pressing
SW6 until the display alters.
SW9 accesses the program mode, enter program mode by pressing SW9 until all green LEDs
on the front panel goes out.
The EE prom values may have to be changed in order to facilitate running with a third party
device unit or a Dual Tower configuration.
SW1
1
2
3
4
5
6
7
8
SW2 9
10
SW3
SW7
SW4
Σ
SW8
SW5
SW9
SW6
PROCEDURE
4 Select setting. Press SW7 until the selected setting is shown on the display. Bin LEDs
indicates
setting #.
5 Change values. Press SW4, the first Repeat step
First digit
digit will show and 4 & 5 to
is now adjustable by verify or
pressing SW7. 8 Σ change
settings.
NOTE: Depending on version of micro processor the total number of settings varies.
When displaying numbers between 10 to 20, third party LED will light up.
When displaying numbers over 20, stacker full LED will light up.
Bin LEDs
PROGRAMMABLE SETTINGS
The value indicated in the right column is depending on version of Microprocessor. For correct default
values see label on side frame of machine.
LED # DESCRIPTION PURPOSE VALUE
1 High / low intensity bin LEDs. Enables double sheet detector to function on thin / 010
thick paper. Value reflects paper thickness. Scale from
10 to 512, where 512 is equal to no paper and 0
represent no light from LED to sensor. If value is set
lower than 010, full LED intensity is switched on.
If increased, full LED intensity is switched on when
running thinner paper.
If decreased, the intensity is altered on thicker paper.
2 Double sheet detection off. Paper too thick for sensor to read. Value reflects paper 100
thickness, same scale as in # 1.
If increased, double sheet detector is switched off
when running thinner paper.
If decreased, double sheet detector is off when running
thicker paper.
3 Maximum limit double sheet Paper too thick compared to calibrated sheet. Value 100
detection. reflects paper thickness, deviation is 1.5 times
calibrated sheet thickness.
If increased, the machine will accept a larger deviation
of paper thickness.
If decreased, the machine will accept a smaller
deviation of paper thickness.
4 Minimum limit double sheet Paper too thin compared to calibrated sheet. Value 130
detection. reflects paper thickness, deviation is 0.5 times
calibrated sheet thickness.
If increased, the machine will accept a larger deviation
of paper thickness.
If decreased, the machine will accept a smaller
deviation of paper thickness.
5 Overlap stacking mode. Regulating overlap between sheets. Value reflects 052
M.Sc. between bin motor starts (0.52 sec.). (110)
If increased, positive overlap increases.
If decreased, positive overlap decreases.
6 Overlap third party device mode. Regulating overlap between sheets. Value reflects 050
M.Sc. between bin motor starts (0.50 sec.). (100)
If increased, positive overlap decreases.
If decreased, positive overlap increases.
7 Speed conveyor belt. Regulating conveyor belt speed. Value reflects tacho 130
meter pulses / sec.
If increased, conveyor belt speed increases.
If decreased, conveyor belt speed decreases.
8 Minimum cycle time offset Regulating collating speed. Value reflects 1.71 sec. per 171
stacking mode. set.
If increased, speed in offset mode increases.
If decreased, speed in offset mode decreases.
9 Minimum cycle time straight Regulating collating speed. Value reflects 2.00 sec. per 200
stacking mode. set.
If increased, speed in straight stacking mode increases.
If decreased, speed in straight stacking mode
decreases.
10 Minimum cycle time third party Regulating collating speed. Value reflects 1.33 sec. per 133
device A4 (8.5"x11") sheet size. set.
If increased, speed increases with A4 sheets in third
party device mode.
If decreased, speed decreases with A4 sheets in third
party mode.
NOTE:
Time settings 22 and 23 are only in use if Collator is used on-line as a Dual Tower System.
Always check microprocessor label, placed on side frame operator side for accurate default
values. Values might change depending on microprocessor version.
Refer to installation instruction for time settings that alters depending on third party device.
COMPONENT LIST
Rear view
RE 1
(Only on
310 B collators) RE 2 (Only on
310 B collators)
SW 11
(Only on
310 B collators)
F3 MOT 1 - 10
SOL 1
F4
TRANSFORMER
SOS 2
TR 1
Connector J5
PCB 90-2
Connector J6 MOT 11
F1
AC RECEPTACLE
Connector J4 J7
SOS 1
Front view
PCB 90-1 Connector J1
Connector J3
Connector J2
LED 11
SW 12 LED 12
(Only 310 B
Collators)
SW 10
PHT 1 - 10
LED 1 - 10
The five DIP switches are located on the circuit board 90-1.
To access the DIP switches Front cover has to be removed according to CRI 1.1.
Home position for all switches is in the left position exept for switch no. 4 that determines if the
circuit board should be operated as a 6 station Collator or a 10 station Collator.
Left view
2 2
3 10 Station mode 6 Station mode
4
5
Power to circuit board ON OFF
The AMP receptacle is the third party device connector J7. In below table you will find a
description of the function on each pin and what it is connected to.
Jumpers can be put across the connector J7 in order to reduce the speed on the collator if
for example connecting a third party device.
In below table a description of the different speed reductions is shown.
PURPOSE
From Version 96 the Microprocessor is equipped with a Self Diagnostic System Control
( SDS).
If entering the SDS mode the machine will check the function of all electrical systems
( incl. Micro processor ) in sequences. This will assistance you when trouble shooting a Machine.
When using the SDS mode, Test Connector p/no. 900211 should be plugged into connector J7 in
order to get the correct signals from the Third Party Device Connector . The SDS mode will still
be functional without the Test Connector, but with limitations in the control of Connector J7.
From Version 96 the Microprocessor is also equipped with an Electrical Burn in Program
( EBP ), the EBP is mainly used in the manufacturing process to eliminate faulty components but
can also be to some assistance when trouble shooting.
The EBP normally runs for 24.000 modified machines cycles ( app. 10 hours) but can be stopped
by switching off the main power switch.
To enter the EBP program press the green start switch at the same time as the main power is
switched on.
SDS PROCEDURE
To start the SDS program, push the calibration button (Yellow) on front panel at the same time as
the Main switch is turned ON. The first thing that appears is that all segments on the display will
be activated, showing 888.
During the first seconds the EE-PROM is thoroughly tested. Then all inputs from the bin
phototransistors are tested, if any input is too high or too low a fault code will be generated and
appears on the display.
1. Before starting the test, front cover should be removed in order to test the DIP switches
on the main circuit board.
NOTE: If front cover is not removed the SDS program can still be used but without any
testing of the DIP switches.
2. Load all bins with paper.
NOTE: It is not necessary to load the bins, the test will however be limited.
3. Push calibration switch (Yellow) at the same time as the main power is turned ON.
Check that all segments on the display are activated. After a few seconds all bin motors
will run for a cycle, all LEDs on front panel lights up.
4. Push all visible buttons on the front panel, a red LED on the panel should go out each
time. If the front cover is off the DIP switches should also be tested, if not go to step 5.
Slide DIP switches 1-4 to the right position (see EDI 4.3 for location), each time a green
LED on the panel will go out.
Slide DIP switches 4-1 back to the left position, an additional green LED will go out each
time a switch is positioned to the left.
NOTE: On a six bin Collator DIP switch number 4 should always be in the left
position during the test.
CAUTION: Do not touch DIP switch number 5 since that would reset the micro
processor to normal mode.
5. If the DIP switches are not accessible press SW9 to continue the SDS program.
6. If the SDS program did not find any faults, 888 will appear on the display again. The first
fault code that has been generated during the test will otherwise show on the display.
By pressing any button on the panel all codes that has been generated will display.
7. Check the fault isolating procedure corresponding with the fault code to determine faulty
parts and to repair.
030 Speed limitation 1500 sets per hour activated in connector J7.
Disconnect Model 91 and connect test plug p/no 900211
Restart the SDS program.
If fault code 030 is generated again, replace PCB 90-1
according to REP 2.1.
If fault code 030 is not generated see fault isolating procedure for
Model 91.
031 Speed limitation 1800 sets per hour activated in connector J7.
Disconnect Model 88 and 89 and connect test plug p/no 900211
Restart the SDS program.
If fault code 031 is generated again, replace PCB 90-1
according to REP 2.1.
If fault code 031 is not generated see fault isolating procedure for
Model 89.
Codes between 035-044 will not be activated if no bins has been loaded with paper.
035 Misfeed in bin 1.
Check loading, clean / replace feed rollers.
036 Misfeed in bin 2.
Check loading, clean / replace feed rollers.
037 Misfeed in bin 3.
Check loading, clean / replace feed rollers.
038 Misfeed in bin 4.
Check loading, clean / replace feed rollers.
039 Misfeed in bin 5.
Check loading, clean / replace feed rollers.
040 Misfeed in bin 6.
Check loading, clean / replace feed rollers.
041 Misfeed in bin 7.
Check loading, clean / replace feed rollers.
042 Misfeed in bin 8.
Check loading, clean / replace feed rollers.
043 Misfeed in bin 9.
Check loading, clean / replace feed rollers.
044 Misfeed in bin 10.
Check loading, clean / replace feed rollers.
PURPOSE
For machines equipped with a microprocessor of a Version 95 or lower the Self diagnostic system
control program is not available. Therefore the trouble shooting has to be done according to
below procedure without any assistance from the SDS program.
PROCEDURE
Front panel does not light up. Power not connected. Check voltage in power cord.
Conveyor belt motor MOT11 Conveyor motor MOT 11 defective. Check for approximately 24 VDC to
does not operate. motor between connector J4 pin 5
and common ground, see REP 2.3
for location.
Micro processor or Main PCB 90-1 defective. Check for approximately 3 VDC to
PCB between connector J2 pin 27
and common ground, see EDI 4.2 for
location.
Feed motor MOT 1-10 does Bin deleted. Press the yellow calibration button
not operate. for more than 5 seconds, see
operating instruction for procedure.
Stacker motor MOT 12 does Stacker plate jammed. Check for mechanical bindings.
not operate.
Stacker motor MOT 12 Excessive light on slotted optical switch SOS If running machine with rear cover
operates continually. 1. off stacker can run continually due
to excessive light on SOS 1, see EDI
4.2 for location.
Main PCB 90-1 defective. Check that the voltage to the PCB is
altering between 0 and 5 VDC when
stacker is activated. Measure
between connector J1 pin 11 and
common ground. See EDI 4.2 for
location.
Bin LED’s 1 - 10 does not LED defective. Check voltage between both of the
light up. pins on the LED , voltage should not
be more than 1.5 VDC.
Bin indicator LED’s on panel Optical path between LED and Remove paper / clean PHT 1-10 and
stays on. phototransistor on bin is blocked. LED 1-10. Check reading on sensor,
see REP 2.10 for instructions.
Conveyor door LED on panel Interlock magnet INTKL 1 defective / Check for 0 VDC between connector
stays on. misadjusted. J2 pin 5 and common ground. See
wiring / circuit diagram EDI 4.4 for
exact pin number.
Double sheet detection / Bin LED 1-10 or PHT 1-10 misadjusted. Adjust according to REP 2.10.
misfeed detection fails.
Total / preset counter fails. Software failure / Main PCB 90-1 faulty. Make a reset of EE-prom, see PRG
3.1 for procedure.
Stacker LED on panel stays Loading lever in load position. Check function of load lever.
on.
Power supply PCB 90-2 defective. Check for 24 VDC from PCB
between connector J5 pin 5 and
common ground, see REP 2.3 for
location.
Shunt solenoid SOL 1 fails to No third party device (TPD)connected. Check connection of TPD or if TPD
operate. is shut off.
PURPOSE
Parts that needs to be cleaned / checked / replaced after a certain number of machine cycles
(N.M.C) is described in below table. Cleaning of feed rollers is not included, this is highly
depending on the type of job that the Collator is being used for and needs to be done regularly or
whenever feeding problems occurs.