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The following tools are required for servicing the FN4 Remote and TP4 Remote:
Open-ended spanner WAF 7, WAF 10, WAF 13
Hexagonal socket spanner WAF 2, WAF 2.5, WAF 3, WAF 4, WAF 5
The tools are available from Ernst Nagel GmbH.
2
Copyright © 2001 Ernst Nagel GmbH FN4/5 & TP4/5 Remote Service-E 10.08.2001
Index
Index........................................................................................................................... 3
Precautions ................................................................................................................. 5
Main differences between FN4 and FN5 ........................................................................ 6
Main differences between TP4 and TP5......................................................................... 6
General view of FN4/5 Remote ..................................................................................... 7
FN4/5 connection options ............................................................................................. 8
What the FN4/5 Remote can do .................................................................................... 9
System overview FN4/5.............................................................................................. 10
FN5 control................................................................................................................ 11
FN4 Remote software ................................................................................................ 11
Principle of function.................................................................................................... 12
TP4/5 Remote (option) ............................................................................................... 12
Shift tray (option)........................................................................................................ 12
Mechanical arrangement ............................................................................................ 13
Electrical arrangement ................................................................................................ 17
Connections of the FN4/5 ........................................................................................... 18
Wiring diagram FN4 ................................................................................................... 19
Wiring diagram FN5 ................................................................................................... 20
Adjustment options..................................................................................................... 23
FN4 control panel....................................................................................................... 25
Changing the paper format ........................................................................................ 27
FN5 control panel....................................................................................................... 29
Offline mode .............................................................................................................. 30
FN5 software specifics (from SW v009): ...................................................................... 30
Stapling head positions............................................................................................... 31
Stapling options ......................................................................................................... 32
Refilling staples.......................................................................................................... 33
Stapling problems ...................................................................................................... 34
Staple jam and staple magazine empty........................................................................ 34
Altering the gap between the fold rollers ...................................................................... 35
Installation instructions ............................................................................................... 36
Repairs...................................................................................................................... 37
Service parts for the FN4/5 REMOTE .......................................................................... 38
Diagnosis software FN4/5........................................................................................... 39
Replacing the staple head link (FN4 only) .................................................................... 41
Position of sensors / microswitches in the FN4/5 Remote.............................................. 42
Troubleshooting the FN4/5.......................................................................................... 43
Description Sorter FN................................................................................................. 45
General view of TP4 Remote ...................................................................................... 46
How the TP4/5 works ................................................................................................. 47
Connecting the Trimmpress to an FN4/5...................................................................... 48
Power up TP4/5 REMOTE.......................................................................................... 49
Wiring diagram TP4.................................................................................................... 50
Wiring diagram TP5.................................................................................................... 51
TP4 control panel....................................................................................................... 53
Adjustment of the feed belt ......................................................................................... 54
Adjustment of the discharge belt ................................................................................. 54
Adjustment of overlap on conveyor.............................................................................. 54
Adjustment of the paper stop ...................................................................................... 55
Turning the machine by hand ...................................................................................... 56
3
Over current circuit breaker......................................................................................... 56
Adjusting the photoelectric sensor ............................................................................... 57
Adjustment of the upper dead center (U.D.C.) of the blade stroke ................................. 58
Replacing and adjusting top and bottom blade ............................................................. 59
Position of sensors / microswitches in the TP4/5 Remote.............................................. 61
Troubleshooting the TP4/5.......................................................................................... 62
4
Precautions
Ensure:
the connection between CLC and FN5 is secured with screws
the connection between FN5 and TP5 is secured with screws
the mains connector is easily accessible
that the brake switch is in position 1 (brake is activated) and the cover over the
switch has been put back on
that fuses are always replaced with the same type and value
that the machine is unplugged if working inside of it
that the IEC outlet of the FN5 isn’t used for anything else but the TP5
that you follow the precautions described in the chapter knife replacement as
this is the most hazardous area of the system
that long hair or loose cloths don’t get caught in turning parts or moving belts
that you secure open covers with the provided stop
that you guide the covers when closing them, don’t pinch your fingers
that mains voltage and the voltage of TP5 match (two different versions)
Service interval: Both machines need no regular maintenance, but it is

recommended to check belts, knife and infeed rollers while servicing the Color
Laser Copier
USA only:
the mains outlet needs to be fuse protected by a 16 A fuse
5
Main differences between FN4 and FN5
Higher speed due to direct communication with CLC 5000
The FN 5 is now able to handle paper formats up to 12”x18”
The FN 5 handles minimum sizes down to A5R, STMT-R in straight pass mode
The FN 5 has an improved paper path
The FN5 handles voltages between 100 and 240 V w/o jumpers (switching power supply)
The FN5 has a 2x 16 character LC Display for improved error handling and adjustments
Cover with pocket pull
Different interlock switches
Motors and solenoids are either fuse or over temperature protected
Main differences between TP4 and TP5

The TP 5 is now able to handle paper formats up to 12”x18”
The TP 5 has an emergency stop switch
Cover with pocket pull
Different interlock switches (waste paper drawer)
Solid state relays instead of mechanical relays for improved reliability
Motors and solenoids are fuse protected
The TP5 is available as 230 and 200/208 version
6
3 4
2
6
General view of FN4/5 Remote
1 Belt stacker
2 Stacking cover
3 Infeed module
4 Control panel
5 Main switch
6 Conveyor wheels
7
FN4/5 connection options
FN4/5 front (sheet feed)
5 7 8 9 10
FN4/5 rear (sheet delivery)
11 12 13
5 Main switch
7 Primary Fuse F1 T 2,5A HBC
8 Secondary Fuse F2 T10A
9 IPC Interface to CLC (FN4: Connection for patch cable (PC link)
10 Mains connection for FN4/5
11 Mains connection for TP4/5 Remote
12 Bus connection for TP4 Remote
13 Connection for conveyor
8
What the FN4/5 Remote can do
§ Stapled booklets
max. 16 single sheets (max. 105 gsm) = 64-page brochures
§ 2 or 4 stapling heads (5000 staples each)
§ Stack delivery max. 1000 sheets
§ A4 (duplex only), A4R, A3, A3+ and 12”x18” formats (FN4: only up to A3+)
§ Automatic format adjustment
§ Offline finishing via manual unit
§ Controlled by FN4 Remote software
§ Duplex online finishing from 64 gsm to 105 gsm only (FN4: from 80 gsm)
Options:
§ Loop staple stapling heads (210 staples each)
§ TP4/5 Remote for front edge trimming
§ Collator (up to approx. 150 compartments)
9
System overview FN4/5
The FN5 is able to communicate with the CLC via IPC light protocol.
10
FN5 control
The FN5 is fully controlled from the CLC, Color Pass respectively
Detailed information will be made available by Canon
FN4 Remote software

A prerequisite is the use of a RIP. Installation instructions will be issued by Canon.
The FN4 Remote

software was
developed as the CLC
1000 does not provide
an interface to the
appropriate command
for controlling a
finisher. The software
assumes online
control of the FN4 and
TP4 Remote.
Functions
Programming a job
• Set paper format
• Activate functions (staple, cut, by-pass, collator)
• Indicate number of brochures
• Indicate number of single sheets of a job
• Stop the CLC 1000 if the FN4 reports a fault
• In the event of a fault, provides assistance to the user by means of a clear text error
message.
11
Principle of function
§ Individual sheets fed from CLC 1000

§ Individual sheets collated to form a brochure set
§ Brochure set stapled and folded
§ Brochures delivered onto conveyor
TP4/5 Remote (option)
§ Brochure fold compressed to achieve flat brochures

§ Front edge of brochure trimmed
Shift tray (option)
Offset delivery of individual sheets to ensure separation of sets
12
Mechanical arrangement
13
The functional units of the FN4/5 Remote along the route taken by the paper are described
below.
Paper feed
As on the one hand, the CLC 1000 has a variable paper delivery speed as a function of
thickness and type of paper etc., but on the other hand there is no information available
about current speed, the paper feed has to be able to cope with these differences in
speed.
The CLC 1000 pushes an individual sheet into the FN4. It turns the paper feed sensor,
which starts the feed rollers. As soon as the sheet stops, a lifting magnet presses the
pressure rollers against the feed rollers which are permanently rotating in order to draw
the fed sheet into the FN4.
The FN5 works w/o this sensor due to the direct communication between CLC and finisher
Paper feed sensor

The paper feed sensor generates the pulse to count the number of individual sheets fed in.
It also controls the straightening, stapling and collator functions and detects paper jams in
this area of the FN4/5.
Paper divert
A solenoid activated diverter directs the incoming sheets either to stack delivery or to the
stapling area.
14
Stack delivery tray
The stack delivery tray considerably increases capacity compared to the customary
delivery tray on the printer.
It can take up to 1,000 sheets, allowing production to take place without supervision.
An optional sorter can be fitted in the stack delivery tray instead of the delivery cover to
separate individual sets by offsetting them laterally.
Collection stage
After being diverted through the paper divert, the sheets slide over a collection stage. The
drop in height results in the sheets dropping onto one another.
Stapling area
The sheets drop until they reach the stapling stop. All the following sheets of a brochure
set accumulate at this point. The lateral stops push the collected stack of paper straight
after every sheet, in order to ensure that the sheets lie exactly on top of one another.
Folding area
The folding device works in accordance with the knife-folding principle and consists of the
following parts:
• fold knife
• fold knife drive
• fold knife sensor
• fold rollers
• fold roller drive
In the folding process, the brochure is pushed through the fold rollers from underneath by
the fold knife. The fold rollers rotate during this process and transport the brochure to the
conveyor tray. The gap between the fold rollers can be adjusted by a lever depending on
brochure thickness and paper quality.
15
Stapling device
The stapling device consists of the following parts:
• stapling head strip

• driver strip
• die plate strip
• stapling drive
• stapling stroke sensor
• stapling heads
The stapling heads are fitted to the stapling head strip. A maximum of 4 stapling heads
simultaneously is permitted, there being 6 possible stapling head positions.
For stapling, an electric motor draws the stapling head strip downwards until the stapling
head is resting on the paper. The drivers of the stapling heads are then drawn downwards
by the driver strip. This process pushes the staple through the paper and bends it over
against the die plate strip beneath.
Stop slide
After the stapling process, a lifting magnet draws the stapling stop downwards. The
stapled paper drops onto the fold stop as a result, triggering the folding process via the
fold position sensor.
Conveyor tray
After folding, the brochure drops onto the conveyor tray. The fold rollers transport it to
underneath the conveyor wheel. The conveyor belt starts up briefly. The conveyor wheel
prevents the brochure opening and thus ensures that brochures are neatly imbricated on
the conveyor belt. This makes the brochures easy to remove and pack up.
16
Electrical arrangement
The FN4/5 is controlled by a microcontroller on the motherboard. Motor cards control the
DC motors. A control panel with 8 keys and 8 dual LEDs is provided as the operator
interface. All boards are connected by a serial bus with a flat cable.
The FN5 has an additional 2x16 character LC Display for adjustments and error messages
Motherboard
§ 80C517 microcontroller
§ EPROM program memory (control software)
§ EEPROM memory for set values (e.g. format sizes, counter etc.)
§ Inputs for sensors and switches
§ Outputs for actuating lifting magnets and DC motors
§ RS485 bus interface
§ RS232 interface for communicating with the command workstation
The FN5 has an additional piggy back board which provides an IPC light interface for
direct communication with the CLC
Motor card
§ Power transistors to actuate a maximum of 4 DC motors
Control panel
§ 8 dual LEDs
§ 8 keys
17
Connections of the FN4/5
Inlet side
FN4: RJ45 jack : RS232 interface for communicating with the command
workstation
FN5: Sub-D IPC Interface
Equipment socket : voltage supply
Outlet side
Latched socket : connection for conveyor tray
9-pin Sub-D : RS 485 bus to trimmer
Equipment socket : voltage supply for the trimmer
Side wall of unit, operator side

6-pin socket : connector for sorter
Interlock system
The operator/service engineer is protected by a hardware interlock system when
accessing the interior of the FN4. In other words, the 24 V power supply is interrupted by
a serial connection of switches which then switch off all drives.
Software update
The FN4 control software is updated by replacing the EPROM on the motherboard.
The FN5 control software is updated by replacing the EPROM on the IPC board.
Important: insert EPROM with semicircular finger-shaped recess facing upwards, flush
with the top edge of the base.
18
Wiring diagram FN4
19
Wiring diagram FN5
20
21
22
Adjustment options
Symmetry of staple bending

The position of the stapling head strip has an effect
on the symmetry of staple bending.
The strip can be moved to the left or right.
Parallelity of staple limbs

If the staple does not hit the exact center of the die plate,
the limbs of the staple will not be bent in a line.
The position of the stapling heads in relation to the
die plates can be altered by swiveling the stapling frame.
Positioning the staples in the fold

The staple and fold stop is responsible for positioning
the staples in the fold.
• The stops must be aligned parallel to the fold rollers.

• The angle between the lateral stops and the fold
rollers must be 90 degrees.
• The gap between the staple and fold stop must correspond to the gap between the
staple and fold position.
It is important not to force the paper stack when straightening it. The resulting corrugation
forces staples out of the fold.
23
Symmetry of the brochure
The fold stop is responsible for the symmetry of
the brochure.
• The fold stop must be aligned parallel to the

fold rollers.
Positioning the fold

The gap between the stop slide (fold stop) and the fold position is responsible for
positioning the fold in the center of the brochure.
Important!
When adjusting the stop slide,
adjust the collection stage
accordingly.
Lateral stack straightening

The lateral stops are responsible for the lateral stack straightening of the brochure.
If the brochure is not absolutely straight, the gap between the lateral stops can be adjusted
using the control panel in Setup mode. Note that lateral stops which are set too close
together can also lead to poor results.
Straightening stack in the longitudinal direction

The collection stage is responsible for straightening the stack in the longitudinal direction.
This can be adjusted using a setscrew.
24
FN4 control panel
LED Type of display Description

ONLINE green FN4 is online
flashing gre en FN4 is online + job still active
(programmed)
red general fault
flashing red communication fault
off FN4 is offline
SET flashing green Setup mode active

flashing red mechanical fault
green stapling switched on

flashing red staples empty or stapling malfunction
off stapling switched off
green cutting switched on

flashing red mechanical fault/paper jam
red cover open/paper compartment open
off cutting switched off
A4, A4R, A3, A3+ green paper format set

flashing green manual format selection
flashing red stops in process of being moved
25
Key
Switch between online/offline

Only possible if no job has been programmed!
1. Reset error messages

2. Delete a job (display flashes green while online)
Stapling on/off
Only possible in offline mode!
Cutting on/off
Switch to TP4 Remote menu
Keep key depressed for 5 seconds
Only if TP4 Remote present
Start stapling and folding procedure

Switch to Setup mode

Paper size smaller/larger
Manual adjustment of format size

Appropriate LED comes on
26
Changing the paper format
The following formats are set by default:
A4, A4R, A3 and A3+
297 305
210
297
A3 420 A3+ 440
A4R 297
A4 210
These formats can be customized.
The max. and min. sizes are:
Format widthmax. 309 mm

Format widthmin. 202 mm
Format length max. 448 mm
Format length min. 210 mm
309
202
448
210 224
105
27
• Select FN4 REMOTE OFFLINE mode.
• Jumper the cover switch.
• Select the FORMAT which is to be changed.
The corresponding LED is lit.
• Press both SET buttons simultaneously.

The SET LED blinks.
Adjustment of format width
• Hold down the STAPLE button
Press the upper set button, the width is decreased

Press the lower set button, the width is increased
The format is changed in steps of 0.2 mm.
Adjustment of format length
• Hold down the TRIMM button
Press the upper set button, the length is decreased

Press the lower set button, the length is increased
The format is changed in steps of 0.2 mm.
• Press both SET buttons simultaneously to exit setup mode.

The actual settings are stored in the EEPROM and are thus retained when the FN4 is
switched off.
Return to factory settings
To reset the formats to the factory settings the ONLINE button has to be held down while
switching on the FN4 at the main switch (5)
Attention!
The last format settings stored will then be lost.
28
FN5 control panel
The only functions which are controlled from the FN5 panel are
the paper guide adjustment of the FN5, the TP5 set up and the offline mode
LED/Key(s) Display Description

Off FN5 in offline mode
Green FN5 in standby mode
Green flashing job is active, or set up in offline mode
Red FN5/TP5 Error
Red flashing Error, job still active
Reset i.e. after error Not needed if door
was opened
Press for more than 3 sec. to enter
offline mode (press (-) to change
format)
Manual start of stapling & folding in
offline mode
FN5 + + +/- Adjustment of paper width
FN5 + + +/- Adjustment of paper length

3 different correction values for the
following 3 ranges:
1: 210 - 270 mm
2: 270 - 370mm
3: 370 – 457 mm
TP5 + + +/- Trimmer offset
Adjustment of cutting width
TP5 + + +/- Delay time to press position
29
TP5 + + +/- Delay time of out feed belt to align
booklet against booklet stop
TP5 + + +/- On time of belt stacker
Offline mode
To enter press “reset” for more than 3 seconds. The machine adjusts itself to 12”x18” and
goes into offline mode.To change the format press the (-) button until the desired format is
displayed. The machine adjusts itself as soon as the (-) button is released. The green LED
is blinking as long as the paper stops are moving. Feed in the paper and press “start” to
finish it.
FN5 software specifics (from SW v009):
The FN5- SW doesn’t boot w/o a CLC connected (LED’s stay orange) .
unless the reset key is pressed during power up
or DIP-switches 1 to 4 are set = service modes 1 - 4
or DIP-switch 8 is set = assembly mode
• Dip 6 : for old style sensor bracket (folding knife home position)
• Dip 7 : FN4- gear box (12”x18” wasn’t possible).
• Dip 8 : Assembly mode
In assembly mode with DIP-switch 8 “on”:
• Erase user settings by pressing keys FN5 and TP5 during power up.
Confirmation on LC display
• Press key combination “Adjustment of paper width” to keep the paper stops at their
innermost position. Back to outer position by pressing “Reset”
• Normal position of paper stops after power up is A3
• FN5 + “Reset” → Paper stops to A4.
• FN5 + Key # 4 → Paper stops to A4R.
30
Stapling head positions
The FN4 has 6 stapling head positions in
which a maximum of 4 stapling heads can be
inserted simultaneously.
The 5000 stapling head and the loop staple stapling heads cannot be mixed due to the
different stroke height of the driver.
Changing stapling head:

• pull stapling head connecting cable out of connecting socket
• unscrew black clamping screw
• take stapling head off stapling head bar
• When installing the head at a new position make sure the driver is pulled out
• plug stapling head into appropriate position on stapling head bar
• screw clamping screw tight
• plug stapling head connecting cable into connecting socket
Possible combinations B A A B
Stapling head position 1
2x 5000 stapling head

Always use connectors “A”
124
B A A B
2x 5000 stapling head or

2x loop staple stapling head
Always use connectors “A”
80
B A A B
4x 5000 stapling head or

4x loop staple stapling head
Use “A” for inner “B” for outer heads
194
31
Stapling options
A4R (297x210) format
Stapling head Stapling head Stapling head

2x 5000 stapling 2x 5000 stapling 2x loop stapling
Nagel staple Nagel staple Nagel 26/6 loop
A4 (210x297) format
Stapling head Stapling head Stapling head Stapling head

2x 5000 stapling 4x 5000 stapling 2x loop stapling 4x loop stapling
Nagel staple Nagel staple Nagel 26/6 loop Inside 26/6 loop
magazine magazine staples staples
A3 (420x297) format

A3+ (440x305) format

32
Refilling staples
Nagel staple magazine for
5000 stapling head:
The red hoop on the staples in the new cassette should always be pulled out 3 centimeters
and torn off at the marking on the cassette (STAPLE TEAR LINE).
Never push staples into the cassette. This is prevented by a fitted stainless steel spring
and would lead to staples jamming in use.
Nagel 26/6 loop staples and Nagel 26/6 staples for

loop staple stapling head
Pull the black slide backwards and upwards until it engages. Then swivel the staple cover
up and away and insert a new block of staples. Close cover again and allow slide to slide
forwards.
Important
Do not allow the slide to snap forwards, otherwise it will be damaged by the stapling head.
33
Stapling problems
One of the causes could be stapling heads which aren’t installed correctly (driver not
pulled out). This would lead to a locked staple stroke motor. The staple stroke motor is
protected by it’s own fuse, which would blow in this case. This fuse (F14) is operator
accessible. It is at the same end of the FN5 where the ON/OFF switch is located. Please
replace it with a 250V T2.5 A type.
Staple jam and staple magazine empty

If the staples are used up or if there is a staple jam in the stapling head, this is indicated by
the staple indicator (red).
Eliminating a staple jam in the 5000 stapling head

§ Remove stapling head
§ Take out staple magazine
§ Actuate stapling head driver by repeatedly pressing on the white button until all the
defective staples have been removed from the staple channel.
Eliminating a staple jam in a loop staple stapling head

§ Remove stapling head
§ Take out staple block
§ Actuate stapling head driver by repeatedly pressing on the
driver angle (10) until all defective staples have been removed from the staple
channel.
If it is not possible to eliminate a staple jam in the way

described above, you have an additional option in the
case of the loop staple stapling head:
10
§ unscrew screws (8)
§ take off driver (6), guide plate (7) and staple
saddle (9) 6
§ eliminate staple jam
§ when reassembling, initially screw up screws (8) 7
only slightly
§ Insert driver (6) into the driver channel from above 9 8
Warning! Engraved “26” must point in the
direction of the staple saddle
§ Tighten up screws (8)
Do not dismantle the stapling heads any further than described above, otherwise the
factory settings to the die plate (via the stapling head strip) will be lost.
34
Altering the gap between the fold rollers
In its central position, the roller nip is 0.7 mm, corresponding to the default setting.
In order to improve fold quality and conveying in the case of extreme papers, it can be a
good idea to adjust the roller nip.
This is adjusted using

the knurled screws on
the left and right of the
inside of the side walls
above the conveyor
tray.
Undo the knurled screw on the left and right, push into the desired position and tighten
back up.
To increase roller nip à push knurled screw down.

To decrease roller nip à push knurled screw up.
The notches in the side wall serve to assist. Each notch equals a step of 0.15 mm fold
roller gap.
35
Installation instructions
Preparing the CLC 1000/5000

Remove original centering bolt for the collator and screw centering plates from the FN4/5
accessories pouch onto the CLC instead.
Preparing the FN4/5

Push the FN4/5 towards the CLC 1000/5000 and leave a gap of a few centimeters
Check the feed height of the FN4/5 and correct if necessary
Plug in the interface cable on the feed side at the bottom of the FN4/5
Plug in the mains cable
Push the FN4/5 up against the CLC 1000/5000
Secure the finisher with the screws provided
Without TP4/5 Remote

Install conveyor tray on FN4/5
Install conveyor tray extension
Install the conveyor wheel
Plug latched plug into socket
With TP4/5 Remote

Push Trimpress against the FN4/5 and connect the units using the bolts provided
Install the FN4/5 conveyor tray on the Trimpress
Install the FN4/5 conveyor wheel
Plug latched plug into socket on Trimpress
Preparing the Command Workstation for the FN4

Install FN4 Remote Software on the Command Workstation
Plug dongle into COM1 interface and connect using the FN4 patch cable
The software cannot be installed on a Mac
36
Repairs
Safety specifications
• Perform repairs using only original NAGEL spare parts.
• Perform repairs only with the mains plug disconnected.
• Repairs and work on electrical fittings may be performed only by qualified specialists.
• It is prohibited to remove safety devices and panels and to operate the unit in the event
of damage which puts safety in jeopardy (e.g. damaged mains cable, covers).
• Use machine only for stapling paper and cardboard.
• Lay the mains cable so that it does not present a tripping hazard.
• Operator’s working position: in front of the machine.
• Set up machine in a dry room only.
Motors
All motors with the exception of the stroke motor in the trimmpress are 24 V DC motors.
As the direction of rotation is not monitored by the control unit, it is essential to ensure that
a replaced motor has been connected with the correct polarity.
Solenoids
The correct polarity of connections also needs to be ensured on the supply cables to the
solenoids as these have an internal recovery diode. In the event of incorrect polarity, a
short-circuit will result! The two 40 % duty cycle solenoids have an internal over
temperature fuse which is not replaceable. In the rare case that this fuse is blown the
solenoid needs to be replaced completely.
Microswitches
All microswitches are connected as normally open. As all microswitches used are change-
over types, pay particular attention to correct connection.
37
Service parts for the FN4/5 REMOTE
Service parts
FN4/5 REMOTE & TP4/5 REMOTE
part no. Part description qty. per recomm.

machine stock level
spare parts
2940500 DC-Gear motor 403559 3 1
2940501 DC-Gear motor 403568 3 1
2940502 Dunker-Motor G42x40 88632.02010 1 1
2940111 Mikro switch "Cherry" D419-V1KL, 2 2
until S/N. 98115347
2940263 Mikro switch "Cherry" D439-V1RA 7 2
2957460 Mikro switch V16/1C5 103 1601 3 2
2940200 Controller PCB 1 1
2940205 Motor controller PCB 1 1
2940206 Key board 1 1
2940198 Slotted sensor 8 1
2800166 Display FN5 only 1 1
2940336 IPC board FN5 only
2940530 Voltage regulator FN5 only
294 567 Fuse T 2,5 A for DC motors 9 10
wear parts - feed rollers)

2940105 Assy shaft in feed (2 rollers) FN4 only 2 2
2940098 Assy shaft out feed (2 rollers) FN4 only 2 2
2941148 Assy shaft in feed (3 rollers) FN5 only
2941149 Assy shaft in feed (3 rollers) FN5 only
wear parts - round belts)

294 0090 Rundriemen 261 mm 1 1
294 0091 Round belt 317 mm 1 1
294 0092 Rundriemen 401 mm 1 1
wear parts - tooth belts

294 0122 Zahnriemen 187L Nr.182 619 00 1 1
294 0195 HTD Toothed belt 267-3M-6 1 1
195 0600 Toothed belt 160XL 037 1 1
wear parts - knives)

295 3916 upper knife 1 1
295 3997 lower knife 1 1
38
Diagnosis software FN4/5
Diagnosis software activated by dip switches is available for servicing purposes. The
software includes the following functions:
• checking the function of sensors via the LEDs of the control panel
• checking the function of motors and electric magnets via keys
Dip switch table of functions
Version 1.06 onwards
1 2 3 4 5 6 7 8 Functions
ON OFF OFF OFF OFF OFF OFF OFF Service Mode 1
OFF ON OFF OFF OFF OFF OFF OFF Service Mode 2
OFF OFF ON OFF OFF OFF OFF OFF Service Mode 3
OFF OFF OFF ON OFF OFF OFF OFF Service Mode 4
OFF OFF OFF OFF ON OFF OFF OFF Diagnosis activated via RS 232 FN4 only
OFF OFF OFF OFF OFF ON OFF OFF With microswitch on old units in the form
of a knife and fold position sensor
OFF OFF OFF OFF OFF OFF ON ON Programs position data
To activate, set dip switches and press Reset on controller board (brown button on left of
dip switch bank).
39
Caution Service mode 1
Do not activate the solenoids of infeed module and folding stop longer than necessary.
The max. duty cycle is 40 %. Otherwise the internal over-temperature fuse may blow
40
Replacing the staple head link (FN4 only)
Attention!
If the stapling heads have different links they will not fit together in one machine. In this
case the link of the new head has to be replaced with the link of the old head.
Old link
New link
41
Position of sensors / microswitches in the FN4/5 Remote
Sensor / microswitch Where is the sensor / Function of sensor /

microswitch microswitch
2940198 Slotted sensor 2940273 Folding knife frame Endposition of folding knife
2940198 Slotted sensor 2940153 Sensor bracket Paper control
2940198 Slotted sensor 2940051 Infeed table Infeed paper path control
2940198 Slotted sensor 2940135 Cross bar Position control side stop
2940198 Slotted sensor 2940135 Cross bar Position control step and lower
stop
2940198 Slotted sensor 2940293 Stop slide Folding position reached / start
foldig process
2940198 Slotted sensor 2940006 Bearing Collision control staple head
and side stop
2940198 Slotted sensor 2940006 Bearing Collision control staple head
and side stop
2940263 Microswitch 2940279 Side plate left Endposition staple stroke
D439-V1RA
2940263 Microswitch 2940081 Jogging motor Inner position side jogging
D439-V1RA bracket
2940263 Microswitch 2940081 Jogging motor Outer position side jogging
D439-V1RA bracket
2940263 Microswitch 2940279 Side plate left Reference position side stop
D439-V1RA
2940263 Microswitch 2940279 Side plate left Emergency stop of side stop
D439-V1RA
2940263 Microswitch 2940135 Cross bar Reference position of lower
D439-V1RA paper stop
2940263 Microswitch 2940135 Cross bar Emergency stop of lower paper
D439-V1RA stop
2957460 Microswitch 2940280 Side plate right Cover closed (FN4 only)
V16/1C5
2957460 Microswitch 2940280 Side plate right Handflap closed (FN4 only)
2955273 FN5
2957460 Microswitch 2940181 Side plate infeed Cover over infeed area closed
V16/1C5 table left
42
Troubleshooting the FN4/5
The FN5 in most cases displays a more specific description of the problem.
The solution is the same
Error:
LED ONLINE red
Solutions:
1. Infeed module cover (3) open? Press RESET.
2. stacking cover (2) open? Press RESET.
3. Hand feeding flap at the stacking cover (2) open? Press RESET.(FN4 only)
4. Have you tried to fold without paper? Press RESET.
5. Check for a paper jam in the infeed module. Remove jam, close cover (3) and press
RESET.
6. Check for a paper jam in the folding area. Remove jam, close stacking cover (2) and
press RESET.
Error:
LED ONLINE red flashing (means communication error)
Solution:
Check the communication cable connecting the FN4/5 REMOTE to the command work
station/CLC and press RESET. It may be necessary to restart the FN4/5 REMOTE
software.
Error:
LED SET red flashing.
Reasons:
• Unsuccessful trial to set a certain sheet size.
Solution:
Switch into OFFLINE mode
push RESET
Set the sheet size again.
• Sheets and folding knife get blocked between fold rollers
Solution:
push RESET to get the folding knife back to central position
open the stacker cover
clear sheets out
• Staplers jam in lowest position
Solution:
open the stacker cover
bring the staplers upwards pulling at the stapler bar
close the stacker cover
push RESET
Error:
LED ONLINE red flashing and LED STAPLE red flashing.
Reason:
• At least one stapler is out of staples
Solution:
Reload staples
push RESET
43
• At least one stapler’s electric cable is unplugged
Solution:
Plug it into position.
Push RESET
• Collision about to happen because 4 staplers are mounted when trying to finish A4 or
A4R (side guides would collide with staplers).
44
Description Sorter FN
With the FN4/5 REMOTE installed the CLC-sorter cannot stay in place because its place is
needed for the FN4 REMOTE. The optional Sorter FN can replace the sorting function of
the CLC-sorter.
The Sorter FN will be installed on top of the FN4/5 REMOTE and replaces the standard
stacking cover (2). The device separates sets by offsetting sheets by approximately 3
centimeters. For unloading all sets can be taken out at a time by hand.
The FN4/5 REMOTE

Software activates and
10
controls the Sorter FN. Sheet
size adjustment is by the
operator. Adjust the sheet
size by loosening the knurled
screw (8) and shifting the
stop (7) into place. The sheet
sizes given on the Sorter FN
are a guideline only. Results
can improve by shifting the
stop (7) away from the sheet
size mark slightly, depending
on paper stiffness and curl.
7 8 9
The optimum position of the stop (7) is achieved when the weights (9) stop the incoming
sheets accurately.
You can feed sets offline into the FN4/5 REMOTE by lifting the flap (10) to access the
infeed area.
Note: Sheets with little stiffness and body may not flow into the sorter properly. If so try
using stiffer paper with more body.
45
9 4
A 20
20
5
2 20
1 6
20
10
11
3
8 7
General view of TP4 Remote 20
1 Belt stacker Seen from inside
2 Conveyor wheels 14 innenliegend
13 15
3 Socket for belt stacker
4 Cover F2 F1
F3
5 Infeed table
6 Link brackets
7 Waste paper drawer
8 Opening to insert hand wheel
9 Hand wheel
10 To power outlet at FN4/5 Remote
11 Bus cable for FN4/5 Remote – TP4/5 Remote
12 Stroke motor brake switch
13 Overcurrent circuit breaker for stroke motor 2,5A 12
14 Fuse slow blow T4A (motor controller)
15 Fuse slow blow T1A (transformer) 20
46
How the TP4/5 works
The brochure coming out of the FN4/5 (26) drops onto the feed belt (20) and is conveyed
to under the blade bar (24).
Here it is detected by the photoelectric reflex switch (23) .
This stops the feed belt (20) and triggers the working stroke of the blade (25).
During this process, the blade bar (24) presses the spine of the brochure (26).
Once the stroke is complete, the feed belt (20) switches back on and the brochure runs
through under the blade onto the discharge belt (21). From here it is conveyed to the
paper stop (28).
Here the brochure (26) is detected by the photoelectric reflex switch (27).
This stops the discharge belt (21) and the brochure stops at the paper stop (28).
A further brochure which has meanwhile run onto the feed belt (20) from the FN4/5
triggers the next working stoke.
As a result, this brochure is pressed down at the spine and the previous brochure at the
paper stop (28) is cut.
After a completed stroke the discharge belt (21) starts, the paper stop (28) is lifted and the
cut brochure is transported to the conveyor (22). A photoelectric reflex switch (30) located
at the exit of the TP4/5 detects the exiting brochure and controls the transport belt (22) of
the conveyor.
If no subsequent brochure triggers a stroke, a brochure at the paper stop (28) will be cut
by automatic triggering off the stroke after approx. 15 seconds and discharged via the
discharge belt (21).
47
If the trimming operation is not desired it can be switched off from the FN4/5 Remote
software or from the FN4 operator panel.
The brochure will then run through the trimmer without being cut.
If there is a paper jam under photoelectric reflex switches (23), (27) and (30), it is indicated
by a red Online LED and a red blinking Trim LED.
In most cases the jam can be cleared by pressing the RESET button. Cover and drawer
of the TP4 have to be closed.
If in the event of a jam, a power outage or if somebody has opened a cover the stroke of
the blade has been interrupted before reaching the upper dead center (U.D.C.)– blade and
blade bar will obstruct the paper transport. In this case the machine has to be turned to the
U.D.C. by following the instructions in chapter “Turning the machine by hand”. Once the
jam has been removed, the machine must be made ready again by means of a reset
stroke. This is achieved by closing the safety cover and pressing the RESET button.
A full waste paper drawer is detected by photoelectric reflex switch (18). It is displayed by
a red Trim LED without stopping the machine.
The error - cover or drawer not closed -is displayed by red Online and Trim LEDs
Connecting the Trimmpress to an FN4/5

Switch off the main switch at the FN4/5
An already mounted conveyor at the FN4/5 needs to be removed first. Start with the
wheels (see #6 general view FN4/5) in order to remove the conveyor table (#1, GV of
FN4/5). After the removal of the table reinstall the wheels (#6) again at the exit of the
FN4/5.
The bus cable between FN4/5 and TP4/5 (11, GV of TP 4/5) is stored in the drawer (7) it
needs to be plugged in underneath the infeed table (5).
Slide the TP4/5 close against the FN4/5. Connect power (10) and bus cable (11) to the
appropriate outlets at the FN4/5. Then close the gap between the two machines by sliding
the TP4/5 as close as possible against the FN4/5. The infeed table (5) and link brackets
(6) of the TP4/5 protrude into the FN4/5.
Open the cover (4) and secure the TP4/5 by installing the provided screws (drawer) into
the link brackets.
Install conveyor table and conveyor wheels (1+2) at the back side of the TP4/5. Plug the
cable into outlet (3).
Make sure two sets of conveyor wheels are installed. One between FN5 and TP5 and a
second one at the exit of the TP5
48
Power up TP4/5 REMOTE
The TP4/5 Remote gets power and control signals from the FN4/5 Remote.
After the two machines have been connected by a service technician the system can be
switched on at the FN4/5 main switch.
The TP4/5 then performs a cycle to empty the machine. By starting feed and discharge
belts, lifting the stop and starting a reset stroke of the knife. FN4/5 and TP4/5 adjust their
format to A3. The following LEDs on the FN4 display are lit green:
ONLINE
STAPLING
TRIMMING
A3
The system is now ready
The FN5 is ready as soon as the online LED is green
49
Wiring diagram TP4
50
Wiring diagram TP5
51
52
TP4 control panel
The TP5 control panel is part of the FN5 control panel
Switch to TP4 remote menu by pressing this button for 5

seconds.
Only in Offline mode possible!
Only if TP4 is connected!
As long as you are in the TP4 remote menu the lower left hand LED blinks green.
Delay time feed belt
Delay time discharge belt
Cutting width
Delay time conveyor belt
Test TP4
Together with the four buttons in the left column to adjust the
settings in 12 steps. Displayed by four LEDs. Each hit
increases or decreases the setting by one step.
Store settings and leave TP4 Remote menu
53
Adjustment of the feed belt
The delay of the feed belt (20) needs to be adjusted that the spine of the brochure (26)
stops in the middle of the press bar (31). If it stops too early or too late, it can be corrected
by changing the delay of the feed belt (20) from the FN4/TP4 operator panel. This
adjustment is even more important with loop staples, as a delayed stop would transport
the staples underneath the blade and could damage it.
To correct the delay press the uppermost button of the left column of the TP4 menu
(symbol feed belt). By pressing the “+” or “–“ button in the right column at the same time
the delay can be corrected. The new setting is stored by pressing the EXIT button.
For the TP5 press the second button from the top in the left column and buttons TP5 and
+/- at the same time
Adjustment of the discharge belt

The stop of the discharge belts (21) triggered by the photoelectric sensor (27) should be
adjusted in a way that the spine of the brochure (26) touches the paper stop (28) in it’s
entire length. If that’s not the case the delay of the discharge belt needs to be increased,
unless anything else hampers the correct transport of the brochure.
For that: press the second button from the top in the left column and at the same time the
“+” button in order to increase the delay of the discharge belts.
Please watch the following: An unnecessary long delay of the discharge belts (21),
especially with thick brochures or thin covers, causes the lowest sheet(s) to travel although
the spine has already stopped at the paper stop. After the cut the lowest sheet flexes back
and sticks out a little bit.
In this case decrease the delay by pressing the second button and the “-“ button at the
same time. Store it by pressing “EXIT”.
For the TP5 press the third button from the top in the left column and buttons TP5 and +/-
at the same time
Adjustment of overlap on conveyor

The overlap of the booklets on the conveyor is determined by the delay of the conveyor
belts. This delay is adjustable.
For that: press the fourth button from the top in the left column and at the same time the
“+” or “-“ button in order to in- or decrease the delay of the conveyor belts. The delay
54
should be long enough that the brochure completely exits the TP4. Store the setting by
pressing “EXIT”.
For the TP5 press the fourth button from the top in the left column and buttons TP5 and +/-
at the same time
Adjustment of the paper stop

The dimension T of the paper stop (28) is set during ONLINE/OFFLINE mode to half of the
format of the FN4. Refer to the FN4 user manual: control panel buttons. All formats can be
cut individually with a trimming width from 0 to 15 mm, with the exception of the A4 format
which only allows a trimming width of 7 mm. The trimming width is adjustable from the FN4
Remote software during Online mode or Offline from the FN4/TP4 control panel.
For that: press the third button from the top in the left column (symbol: cutting width) and at
the same time the “+” or “-“ button in order to in- or decrease the width. Store the setting
by pressing “EXIT”.
The dimension T varies from 224 mm to 98 m. The trimming width should be increased
with the thickness of the booklet.
For the TP5 press the first button from the top in the left column and buttons TP5 and +/-
at the same time. The trimming width is not controlled from the CLC
55
Turning the machine by hand
For servicing or in the event of faults, it may be necessary to turn the machine by hand.
Open TP4/5 cover (4)

Switch on system at FN4/5 main switch
Remove cover over hand wheel opening (8) and insert hand wheel (9)
Remove cover over brake release
Press brake release switch (12) (position II)
The machine can now be turned by hand (anti clock wise)
When servicing is complete:
Turn machine to upper dead center (blade bar right at top)

Important: press brake release switch (12) again (position I), to close the brake of the
stroke motor. Failure to do so prevents the blade bar from stopping at the upper dead
center after a stroke is completed. The undetermined blade position may cause jams or
other problems.
Close cover over brake switch again
Take off hand wheel again
Close cover over hand wheel opening (8)
Check the over current switch (13) and push it back in if it has been tripped.
Close TP4 cover (4)
Over current circuit breaker
The circuit breaker (13) prevents the stroke motor from being overloaded and switches it
off. In this case, eliminate the fault and push circuit breaker back in.
14 13 15
F2 F3 F1
12
56
Adjusting the photoelectric sensor
In the TP4/5 all four sensors need to be set to “D” mode.
• Turn switch (71) anti clockwise to the stop (setting “D”), if not already done
• Turn potentiometer (70) anti clockwise until only the red LED (72) is on
• Turn potentiometer (70) clockwise until the green LED (73) comes on, add about ½
revolution.
70
71
72 73
57
Adjustment of the upper dead center (U.D.C.) of the blade stroke
Remove the right hand side panel of the TP4/5.
The upper dead center is reached, when the edge of the disk 19 (bras) and the edge of the
bearing block are parallel.
Adjust (U.D.C.):
Loosen screws of sensor disk (16) and adjust it by rotating it:
Clockwise Blade stops earlier
Anti clockwise: Blade stops later
Tighten screws again.
parallel
19 16
20
20 18 17
17
20 20
S5 slotted sensor (trim stroke)
18 S6 photoelectric barrier (papertray full)
58
Replacing and adjusting top and bottom blade
Caution!!! Caution!!! Caution!!! Caution!!! Caution!!! Caution!!! Caution!!! Caution!!!
If replacing the knife carry the wrapped knife to the trimmpress, put it on the infeed table
and unpack it there. Use the wrapping material for the old knife. Don’t carry unpacked
knifes as they could slip out of your hand and cause severe injuries.
Make sure your hands and fingers are not inside the machine if the brake is released
Don’t forget to reactivate the brake (position I) and cover the switch again after the repair
is done.
After every replacement of one of the two blades the gap between them needs to be
readjusted. The minimum gap is 0,02 mm, the maximum is 0.05 mm.
Open the top cover of the TP4/5 (4)

For all fitting or adjustment work on the blade, the
pressing device (35) must be unscrewed. Unscrew bolts 36
(36) and take pressing device away to the side. 35
The top blade (37) is screwed to the blade bar (24) with 5
hexagonal M6 x 16 DIN 933 bolts. The bottom blade is
adjusted in relation to the top blade.
The bottom blade (38) is screwed in place with five
cylindrical bolts (39) and supported with four pressure
screws (40).
To avoid injuries while loosening the screws move the
top blade to it’s lower dead center, please follow the
instructions in chapter: “Moving the machine by hand”
Turn the pressure screws (40) back far enough for the
37
bottom blade to be moved away a little from the top blade
with the bolts (39) undone. 24
If replacing the top blade- loosen the 5 screws,

remove two of them and screw them into the free 37 39 38 41
tapped holes of the blade and use them as a
handle.
Now turn the top blade carefully to it’s U.D.C.
remove the remaining three screws and take off
the blade.
If necessary replace the bottom blade and attach it
loosely. After that fasten the top blade loosely and
turn it to downwards to the lower dead center. The 40
top blade may not touch the bottom blade during
this movement. Tighten the screws of the top blade
59
Adjustment of the bottom blade
Use a single sheet of 60 gsm paper as a feeler gauge and place it in the gap between top-
and bottom blade as the distance to be set.
Press the bottom blade (38) against the top blade (37) so that the paper is caught.
Tighten up the bolts (39) a little using a hexagon socket spanner, but not too tight, so that
the bottom blade can still be moved if the pressure screws (40) are turned. The pressure
screws (40) are now positioned gently against the bottom blade.
Carefully turn the top blade (37) up until it comes free. Remove the paper. Turn the blade
down again using the handwheel to ensure that the setting is not too small.
The blades may not touch each other. If necessary repeat the adjustment.
Carry out a test cut with a single sheet of paper by turning the blade with the handwheel. If
necessary, re-adjust the bottom blade by turning the pressure screws. Tighten the bolts
(39) of the bottom knife as long as the top knife is in it’s lower position.
Turn the top knife to the U.D.C.
Turn switch (12) to brake on (position 1), cover switch (12), take off handwheel (9).
Remount pressing device
60
Position of sensors / microswitches in the TP4/5 Remote
Sensor / microswitch Where is the sensor / Function of sensor /

microswitch microswitch
2957460 Microswitch 2940416 Bracket long Cover closed
2955273
2957460 Microswitch 2940418 Support Waste paper drawer in place
2940357 Safety switch
2950465 Photoelectric 2954065 Bracket for Waste paper drawer full
sensor proximity switch
2955280 Photoelectric 2953752 Flange bar Paper path control feed belt
sensor
2955280 Photoelectric 2954144 Support bracket Paper path control paper stop
sensor
2955280 Photoelectric 2940481 Bridge Paper path control discharge
sensor belt
2940198 Slotted sensor 2940481 Bridge Format reference position
2940198 Slotted sensor 2940431 Mounting bracket Format motor position control
2940198 Slotted sensor 2954065 Bracket for Endposition of stroke

proximity switch
61
Troubleshooting the TP4/5
Error:
TP4 REMOTE does not operate.
Solutions:
1. Check if TP4/5 power cord is fully connected to FN4/5
2. Check if TP4/5 communication bus is fully connected to FN4/5
3. Check if fuses 14 or 15 have blown and replace them if necessary.
4. Check if breaker 13 has popped out and push it in again.
5. Check if stroke motor brake switch (12) is in position II, it should be in position I.
Check if TP4/5 knife is down.
That happens with a blunt knife causing excessive friction; or if the TP4/5 cover is opened
right when the knife is down; or if the power supply fails when the knife is down. The units
stroke motor then cannot bring the knife up again. Call a service person to do the
following:
a. switched on FN4/5
b. open inlet for hand wheel (8) and insert hand wheel (9)
c. remove cover over service switch, put stroke motor brake switch in position II
d. turn hand wheel (9) counter clockwise. Stop turning when the knife is in its upper most
position
e. stroke motor brake switch (12) in position I, reinstall cover
f. remove hand wheel (9), ensure breaker (13) is pushed
Have the knife replaced if it is blunt. It is blunt when paper gets stuck between upper and
lower knife.
62
Technical Data
Power consumption:
During operation: FN4 ca. 240 Watt
TP4 ca. 1000 Watt
Standby: entire system 10 Watt
Temperature range:7,5-32,5°C
Voltage range: 230 Volt +/- 5%, 50 / 60 Hz
Humidity range: 30-70% RH non condensing
Noise emission:
During operation: ca. 75 dB (A) +/- 5%
Standby: 0 dB (A)
63
Version From serial no.: Up to serial no.:
1.0 99015830
2.0 01010000
3.0 01040000
64
This publication is
printed on 100%
recycled paper.
PRINTED IN U.S.A.

Nagel Finisher SM DU7-1103-000

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The tools are available from Ernst Nagel GmbH.

the connection between CLC and FN5 is secured with screws

the connection between FN5 and TP5 is secured with screws

the mains connector is easily accessible

that the machine is unplugged if working inside of it

that you secure open covers with the provided stop

Service interval: Both machines need no regular maintenance, but it is

Main differences between TP4 and TP5

FN4/5 rear (sheet delivery)

FN4 Remote software

The FN4 Remote

§ Individual sheets fed from CLC 1000

TP4/5 Remote (option)

§ Brochure fold compressed to achieve flat brochures

Shift tray (option)

Offset delivery of individual sheets to ensure separation of sets

Paper feed sensor

• stapling head strip

Equipment socket : voltage supply

Side wall of unit, operator side

Symmetry of staple bending

Parallelity of staple limbs

Positioning the staples in the fold

• The stops must be aligned parallel to the fold rollers.

• The fold stop must be aligned parallel to the

Positioning the fold

Lateral stack straightening

Straightening stack in the longitudinal direction

LED Type of display Description

SET flashing green Setup mode active

green stapling switched on

green cutting switched on

A4, A4R, A3, A3+ green paper format set

Switch between online/offline

1. Reset error messages

Start stapling and folding procedure

Switch to Setup mode

Manual adjustment of format size

These formats can be customized.

The max. and min. sizes are:

Format widthmax. 309 mm

• Press both SET buttons simultaneously.

Adjustment of format width

• Hold down the STAPLE button

Press the upper set button, the width is decreased

Adjustment of format length

• Hold down the TRIMM button

Press the upper set button, the length is decreased

• Press both SET buttons simultaneously to exit setup mode.

Return to factory settings

LED/Key(s) Display Description

FN5 + + +/- Adjustment of paper width

FN5 + + +/- Adjustment of paper length

TP5 + + +/- Delay time to press position

TP5 + + +/- On time of belt stacker

FN5 software specifics (from SW v009):

In assembly mode with DIP-switch 8 “on”:

Changing stapling head:

Stapling head position 1

2x 5000 stapling head

Stapling head position 2

2x 5000 stapling head or

Stapling head position 3

)-", .%%!