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2S Trimmer<br />
Service Manual<br />
<strong>Nagel</strong> 2S Trimmer
PAGE INTENTIONALLY BLANK<br />
© <strong>Ernst</strong> <strong>Nagel</strong> <strong>GmbH</strong> 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011<br />
2
Contents<br />
TITLE PAGE<br />
CONTENTS ....................................................................................................................................................... 3<br />
1. SAFETY ..................................................................................................................................................... 5<br />
2. GENERAL.................................................................................................................................................. 6<br />
2.1 BASIC INFORMATION ................................................................................................................................... 6<br />
2.1.1 Basic Information............................................................................................................................... 6<br />
2.1.1 Type of machine and TAG ................................................................................................................ 7<br />
2.2 GETTING TO KNOW THE STR....................................................................................................................... 8<br />
2.2.1 Main components overview............................................................................................................... 8<br />
2.2.2 Components overview Inside ............................................................................................................ 9<br />
2.2.2 Components overview Inside .......................................................................................................... 10<br />
2.2.3 Components overview Interlock breaker & Safety block for knife beam......................................... 13<br />
2.2.4 Components overview I-CAN plug & Mode Selection plug............................................................. 14<br />
2.2.5 Rollers and Belts ............................................................................................................................. 15<br />
2.2.6 Interface signals explanation........................................................................................................... 18<br />
3. GLOBAL FUNCTIONALITY DESCRIPTION .......................................................................................... 19<br />
3.1 BYPASS MODE.......................................................................................................................................... 20<br />
3.2 TRIMMING MODE....................................................................................................................................... 24<br />
4. COVERS .................................................................................................................................................. 29<br />
4.1 FRONT COVER ......................................................................................................................................... 29<br />
4.2 REAR COVER ........................................................................................................................................... 30<br />
4.3 UPPER INFEED COVER.............................................................................................................................. 31<br />
4.4 LOWER INFEED COVER ............................................................................................................................. 32<br />
4.5 UPPER OUTFEED COVER .......................................................................................................................... 33<br />
4.6 LOWER OUTFEED COVER.......................................................................................................................... 34<br />
4.7 BASE PLATE COVER ................................................................................................................................. 35<br />
4.8 USER INTERFACE COVER.......................................................................................................................... 36<br />
5. TROUBLESHOOTING............................................................................................................................. 37<br />
5.1 SERVICE PROGRAM MODE......................................................................................................................... 37<br />
5.1.1 Software Version ............................................................................................................................. 38<br />
5.1.2 Diagnostics...................................................................................................................................... 39<br />
5.1.3 Motors.............................................................................................................................................. 40<br />
5.1.4 Solenoids......................................................................................................................................... 41<br />
5.1.5 Sensors and Switches..................................................................................................................... 42<br />
5.1.6 Voltmeters ....................................................................................................................................... 43<br />
5.1.7 Non Volatile Memory (NVM)............................................................................................................ 44<br />
5.1.8 Dead cycle....................................................................................................................................... 45<br />
5.1.9 Calibration ....................................................................................................................................... 46<br />
5.2 FAULT CODE DESCRIPTIONS ..................................................................................................................... 47<br />
5.3 FAULT CODE SOLUTIONS .......................................................................................................................... 49<br />
6. DEFAULT / BASIC ADJUSTMENTS...................................................................................................... 80<br />
6.1 REPLACING KNIVES .................................................................................................................................. 80<br />
6.1.1 Preparation...................................................................................................................................... 80<br />
6.1.2 Removal Upper Knife ...................................................................................................................... 81<br />
6.1.3 Removal Lower Knife ...................................................................................................................... 82<br />
6.1.4 Placement Lower Knife ................................................................................................................... 83<br />
6.1.5 Placement Upper Knife ................................................................................................................... 84<br />
6.1.6 Adjustment Upper Knife .................................................................................................................. 85<br />
6.1.7 Adjustment Lower Knife .................................................................................................................. 86<br />
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6.1.8 Spine Support Knives...................................................................................................................... 88<br />
6.1.9 Testing / Finishing Adjustments ...................................................................................................... 89<br />
6.2 ADJUSTING BOOKLET QUALITY................................................................................................................... 90<br />
6.2.1 Trapezium / Diamond Shape........................................................................................................... 91<br />
6.2.2 Side Trim (Finished Size) ................................................................................................................ 95<br />
6.3 SENSORS AND SWITCHES ......................................................................................................................... 96<br />
6.3.1 Replace Photo Sensors................................................................................................................... 96<br />
6.3.2 Adjusting Photo Sensors................................................................................................................. 99<br />
6.3.3 Replace Switches.......................................................................................................................... 102<br />
6.3.4 Adjusting Switches ........................................................................................................................ 103<br />
6.4 REPLACING / PREPARING SIDE JOGGERS................................................................................................. 108<br />
6.5 ADJUSTING SIDE JOGGERS ..................................................................................................................... 110<br />
6.6 ADJUSTING CHAINS AND SPROCKETS ...................................................................................................... 112<br />
6.7 MOTOR AND ENCODER POSITIONS........................................................................................................... 115<br />
6.8 TAPPING TRANSFORMER AND BLOWN FUSE CONDITIONS........................................................................... 116<br />
6.9 ADJUSTING THICKNESS DETECTION ......................................................................................................... 118<br />
7. PCB’S .................................................................................................................................................... 119<br />
7.1 SOFTWARE DOWNLOAD........................................................................................................................... 119<br />
7.1.1 PCB1 MD6DC ............................................................................................................................... 119<br />
7.1.2 PCB5 MD6DC ............................................................................................................................... 120<br />
7.1.3 PCB6 CPU..................................................................................................................................... 121<br />
7.1.4 PCB8 ............................................................................................................................................. 122<br />
7.2 LED’S & TEST POINTS........................................................................................................................ 123<br />
7.2.1 Motor Drive (MD6DC) PCB1 & PCB5 ........................................................................................... 123<br />
7.2.2 CPU PCB6 & PCB7....................................................................................................................... 124<br />
7.2.3 Softstart PCB4............................................................................................................................... 124<br />
7.2.4 Interlock PCB3 .............................................................................................................................. 125<br />
8. NVM VALUES........................................................................................................................................ 125<br />
8.1 CURRENT NVM VALUES ......................................................................................................................... 126<br />
8.2 ADJUSTING NVM VALUES ....................................................................................................................... 127<br />
8.2.1 NVM Booklet width correction ....................................................................................................... 128<br />
8.2.2 NVM Side Jogger correction ......................................................................................................... 129<br />
8.2.3 NVM Centering correction............................................................................................................. 131<br />
8.2.4 NVM Stop if booklet too thick ........................................................................................................ 132<br />
8.3 RESET NVM VALUES.............................................................................................................................. 133<br />
9. MAINTENANCE..................................................................................................................................... 134<br />
9.1 PREVENTIVE MAINTENANCE TABLE........................................................................................................... 134<br />
9.2 SCHEMATICS .......................................................................................................................................... 135<br />
9.2.1 DTEO-0000-0121-0000................................................................................................................. 135<br />
9.2.2 DTEO-0000-0142-0000................................................................................................................. 135<br />
9.2.3 DTEO-0000-0143-0000................................................................................................................. 135<br />
10. TECHNICAL INFORMATION................................................................................................................ 136<br />
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1. Safety<br />
RoHS<br />
compliant<br />
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- The 2-Side Trimmer may only be plugged in to an approved and by circuit breakers<br />
protected electrical installation, that is secured with a maximum of 16A.<br />
- The outlet socket shall be installed near the equipment and shall be easily accessible.<br />
- Never put your hands, other body parts or anything else then booklets within trimming<br />
specifications in the infeed or outfeed of the 2-Side Trimmer.<br />
- Before cleaning, maintenance or repairs, always be sure to switch off the power switch and<br />
disconnect the appropriate power cord.<br />
- Always follow all warnings marked on or supplied with the equipment.<br />
- The equipment should only be placed on a solid surface with adequate strength to hold the<br />
extra weight of the machine besides the usual maximum load.<br />
- Always exercise care while moving or relocating the equipment.<br />
- Keep magnets and all devices with a strong magnetic field away from the machine.<br />
- Never attempt to perform maintenance or repairs other than described in this manual.<br />
- Never remove covers or guards that are fastened with screws.<br />
- Never install the equipment near a radiator or any other heat source.<br />
- Never override or bypass electrical or mechanical interlock devices.<br />
- In case of unusual sounds or noises, abnormal surface temperature or odours disconnect the<br />
equipments power source immediately and consult a qualified technician.<br />
The manufacturer cannot be held responsible for arbitrary changes in the machine and the<br />
originated damage.<br />
Make sure the 2-Side Trimmer is NOT powered during installation or service activities.<br />
This is a Class A product. In a domestic environment this machine may cause radio<br />
interference. In which case the user may be required to take adequate measures.<br />
Note: A domestic environment is an environment in which one a radio and television receivers<br />
can be expected inside a range of 10 meters of the concerning machines.<br />
The 2-Side Trimmer is RoHS compliant.<br />
ONLY use RoHS compliant replacement parts ordered from SDD.
2. General<br />
2.1 Basic Information<br />
2.1.1 Basic Information<br />
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With the addition of the 2-Side Trimmer STR to the SDD product range, a cost effective full-bleed solution is<br />
available which has a small footprint and is easily to operate. This machine is designed with high reliability in<br />
mind, which means that it has been designed for long run production without any operator intervention.<br />
The main goal of the 2-Side Trimmer, further referred to as STR, is that it can be used for trimming the bleed<br />
off booklet. Booklets with a maximum up to 25 sheets 80g/m2 (100 pages) can be trimmed from 2mm to<br />
35mm on each short edge of the booklet, to a minimum of 200mm and a maximum of 320mm finished size.<br />
Thereby it is also possible to trim asymmetrical. All actions concerning operating the STR and adjusting the<br />
trim settings can easily be done by using the User Interface (UI) on STR<br />
For example, in the schedule mentioned below (Fig. 2.1) is schematically rendered some results which are<br />
possible with the STR by using a different Centre Offset (symmetrical or asymmetrical):<br />
Finished Size:<br />
260.0mm<br />
Fig. 2.1<br />
3,5mm Waste<br />
Centre Offset:<br />
-15mm<br />
33,5mm Waste<br />
33,5mm Waste<br />
Centre Offset:<br />
15mm<br />
18,5mm Waste<br />
Centre Offset:<br />
0mm<br />
3,5mm Waste 18,5mm Waste<br />
Infeed Size:<br />
297.0mm
2. General (<strong>continued</strong>)<br />
2.1 Basic Information (<strong>continued</strong>)<br />
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2.1.1 Type of machine and TAG<br />
It is important to identify the type of machine and state (TAG) of it before carry out servicing activities.<br />
At the Rear cover there is a label which refers to the Type of machine and serial Nr. (Fig. 1.1 & 1.2).<br />
Fig. 1.1 Fig. 1.2<br />
To find out if it is a TAG0, TAG1 or a TAG2 etc. Machine, find the Yellow Square label (Fig. 2.2 & 2.3).<br />
The number that is marked on this label (Fig. 2.4) indicates the type (TAG) of the machine.<br />
If nothing is marked, the type of machine is a TAG0.<br />
Use only the appropriate settings/procedure for the type of machine!<br />
Fig. 2.2 Fig. 2.3<br />
Fig. 2.4<br />
XX XX XX
2. General (<strong>continued</strong>)<br />
2.2 Getting to know the STR<br />
2.2.1 Main components overview<br />
The pictures of the STR in this document can be different than the actual machine!<br />
See the picture below to get familiar with the components of the STR (Fig. 2.5).<br />
All direction are seen from the paper flow direction.<br />
1<br />
6<br />
4<br />
Fig. 2.5<br />
Rear<br />
No. Action<br />
1 Top Cover<br />
2 Booklet Infeed<br />
3 Trim Waste Bin<br />
4 Power switch (inside)<br />
5 User Interface (UI)<br />
6 Booklet Outfeed<br />
Front<br />
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5<br />
Right<br />
3<br />
Left<br />
Bottom<br />
Top<br />
2<br />
Contents
2. General (<strong>continued</strong>)<br />
2.2 Getting to know the STR (<strong>continued</strong>)<br />
2.2.2 Components overview Inside<br />
Motor3<br />
J4/P4<br />
J9/P9<br />
FC3<br />
J-Motor3<br />
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Infeed Outfeed<br />
S12<br />
J3/P3<br />
PCB5<br />
PCB6<br />
S7<br />
Front-view<br />
Motor4<br />
J7/P7<br />
FC1<br />
J-Motor4<br />
S2<br />
S1<br />
J5/P5<br />
Motor6<br />
Fig. 2.7<br />
PCB = print board J-Motorx = Motor conn. Position Sx = Switch position<br />
Jx/Px = Connector position FCx = Sensor position Motorx = Motor position<br />
S8<br />
S9
2. General (<strong>continued</strong>)<br />
2.2 Getting to know the STR (<strong>continued</strong>)<br />
2.2.2 Components overview Inside<br />
PCB8<br />
PCB7<br />
Motor1<br />
J6/P6<br />
FC1<br />
J-Motor1<br />
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Front-view<br />
Outfeed Infeed<br />
S10<br />
PCB1<br />
PCB3<br />
Motor5<br />
TR13<br />
PCB4<br />
FC7<br />
FC4<br />
Motor2<br />
J4/P4<br />
J9/P9<br />
FC3<br />
J-Motor2<br />
PCB2<br />
TR1<br />
DB1<br />
J1/P1<br />
J2/P2<br />
Trafo1<br />
C1<br />
K1+K2<br />
Fig. 2.8<br />
PCBx = Printboard position J-Motorx = Motor conn. Position TRx = Terminal Rail<br />
Jx/Px = Connector position FCx = Sensor position DBx = Rectifier position<br />
Sx = Switch position Motorx = Motor position Cx = Capacitor postion<br />
Trafox = Transformer position Kx = Relais position
2. General (<strong>continued</strong>)<br />
2.2 Getting to know the STR (<strong>continued</strong>)<br />
2.2.2 Components overview Inside<br />
C1<br />
K2<br />
K1<br />
J6/P6<br />
J6/P6<br />
J9/P9<br />
J4/P4<br />
FC6<br />
FC3<br />
J7/P7<br />
J11<br />
J12<br />
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Infeed Outfeed<br />
J3/P3<br />
M1<br />
Motor8<br />
U1 U2<br />
J10<br />
1<br />
2<br />
3<br />
Top-view<br />
PCB4<br />
TR13<br />
S11<br />
Motor7<br />
FC2<br />
S100<br />
CNT1<br />
S19<br />
S3<br />
S4<br />
J8/P8<br />
FC1<br />
S1<br />
S2<br />
S13<br />
Fig. 2.9<br />
J-Motorx = Motor conn. Position PCBx = Printboard position 1 = Docking Bracket<br />
Jx/Px = Connector position Kx = Relais position 2 = Trimmer/Paper Stop<br />
Sx = Switch position Cx = Capacitor position 3 = Transport Belts<br />
Motorx = Motor position S100 = Power switch position<br />
U1 = Netfilter connector CNT1 = Counter position<br />
U2 = Power Outlet connector M1 = Solenoid position<br />
FCx = Sensor position
2. General (<strong>continued</strong>)<br />
2.2 Getting to know the STR (<strong>continued</strong>)<br />
2.2.2 Components overview Inside (<strong>continued</strong>)<br />
J6/P6<br />
J-Motor2<br />
Motor2<br />
Motor7<br />
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Infeed Outfeed<br />
Motor8<br />
Motor3<br />
S12<br />
J-Motor3<br />
J7/P7<br />
Knife Blocks Top-view<br />
J-Motor1<br />
S11<br />
S10<br />
Motor1<br />
Side<br />
Knife<br />
Knife<br />
Side<br />
Motor4<br />
S13<br />
J-Motor4<br />
Fig. 2.10<br />
J-Motorx = Motor conn. Position Sx = Switch position Motorx = Motor position<br />
Jx/Px = Connector position
2. General (<strong>continued</strong>)<br />
2.2 Getting to know the STR (<strong>continued</strong>)<br />
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2.2.3 Components overview Interlock breaker & Safety block for knife beam<br />
Use the Interlock breaker (Fig. 2.13) to override the Interlock switch (Fig. 2.14) for running the system with<br />
open top covers only when an override is really needed.<br />
Use the Safety block for knife beam (Fig. 2.15) to support the Upper Knife Beam for protection in case of<br />
adjusting or replacing Knives.<br />
Use Chapter 4.1 Front Cover or 4.2 Rear cover to remove the cover.<br />
Caution!!! Overriding the Interlock circuit is dangerous! This should only be done by a trained<br />
Service Engineer when no other solutions are possible!<br />
Fig. 2.12 Fig. 2.13<br />
Fig. 2.14 Fig. 2.15
2. General (<strong>continued</strong>)<br />
2.2 Getting to know the STR (<strong>continued</strong>)<br />
2.2.4 Components overview I-CAN plug & Mode Selection plug<br />
Attention!!! Make sure the I-CAN Termination plug [6P3] (Fig. 2.16 & 2.17) is present.<br />
Otherwise communication problems can arise.<br />
Fig. 2.16 Fig. 2.17<br />
Attention!!! Make sure the Mode Selection plug [6P13] (Fig. 2.18 & 2.19) is present.<br />
Otherwise communication problems can arise.<br />
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6P3<br />
Fig. 2.18 Fig. 2.19<br />
Contents<br />
6P13
2. General (<strong>continued</strong>)<br />
2.2 Getting to know the STR (<strong>continued</strong>)<br />
2.2.5 Rollers and Belts<br />
Infeed / Outfeed<br />
D<br />
C<br />
Rollers<br />
No. Description Article code<br />
A Conveyor Roller 2 Cpl.(A) OGMO-0000-0272-0000<br />
B Conveyor Roller 2 Cpl.(A) OGMO-0000-0272-0000<br />
C Conveyor Roller 1 Cpl. OGMO-0000-0052-0000<br />
D Thickness Measurement System OGMO-0000-0737-0000<br />
Belts<br />
No. Description Article code<br />
1 3X Belt (Flat) UU20U 1521-6%x30mm ( ) OMRE-0000-0055-0000<br />
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Contents<br />
Infeed Outfeed<br />
Fig. 2.20<br />
A<br />
1 (3x)<br />
B
2. General (<strong>continued</strong>)<br />
2.2 Getting to know the STR (<strong>continued</strong>)<br />
2.2.5 Rollers and Belts (<strong>continued</strong>)<br />
Infeed / Outfeed<br />
G<br />
Rollers<br />
No. Description Article code<br />
E Conveyor Roller 2 Cpl.(A) OGMO-0000-0272-0000<br />
F Conveyor Roller 4 L=40mm OGMO-0000-0274-0000<br />
G Conveyor Roller 3 Cpl.(B) OGMO-0000-0273-0000<br />
H Conveyor Roller 1 Cpl. OGMO-0000-0052-0000<br />
Belts<br />
No. Description Article code<br />
1 1X Belt (Flat) UU20U 1158-6%x30mm ( ) OMRE-0000-0054-0000<br />
2 1X Belt (Flat) UU20U 1002-8%x30mm ( ) OMRE-0000-0056-0000<br />
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Infeed Outfeed<br />
1<br />
H<br />
E<br />
Fig. 2.21<br />
F<br />
F<br />
2<br />
F
2. General (<strong>continued</strong>)<br />
2.2 Getting to know the STR (<strong>continued</strong>)<br />
2.2.5 Rollers and Belts (<strong>continued</strong>)<br />
Control Board<br />
1<br />
Belts<br />
No. Description Article code<br />
1 1X Tooth Belt T5 107510 L=1075 ( ) OMRT-0000-0002-0000<br />
2 1X Tooth Belt T5 42010 L=420 ( ) OMRT-0000-0003-0000<br />
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2<br />
Contents
2. General (<strong>continued</strong>)<br />
2.2 Getting to know the STR (<strong>continued</strong>)<br />
2.2.6 Interface signals explanation<br />
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INPUT<br />
It is possible that the STR is connected to a previous machine with a 9Sub-D cable.<br />
Through this cable, the STR communicate with the part of the system before the STR, using the X-can.<br />
Signal name Direction Purpose<br />
X Can<br />
(High / Low)<br />
Start In<br />
(High / Low)<br />
Bidirectional bus between<br />
machines in the system<br />
From previous machine (there<br />
called Exit-H/L) -> STR<br />
Carries all communication between<br />
the modules in the system.<br />
Used during system start-up to assign<br />
node numbers for the Can bus.<br />
OUTPUT<br />
It is possible that the STR is connected to a next machine with a 9Sub-D cable.<br />
Through this cable, the STR communicate with the part of the system after the STR, using the X-can.<br />
Signal name Direction Purpose<br />
X Can<br />
(High / Low)<br />
Exit Out<br />
(High / Low)<br />
Bidirectional bus between<br />
machines in the system<br />
From STR -> next machine<br />
(there called Start-H/L)<br />
Carries all communication between<br />
the modules in the system Exit-H/L.<br />
Used during system start-up to assign<br />
node numbers for the Can bus.<br />
INPUT<br />
It is possible that the STR is connected to a previous machine with a 15Sub-D cable.<br />
Through this cable, the STR communicate with the part of the system before the STR.<br />
Signal name Direction Purpose<br />
Alternate Interface<br />
Start<br />
From previous machine -> STR To start the STR externally.<br />
Alternate Interface<br />
Ready / Not ready<br />
From STR -> previous machine To give the status from the STR to<br />
the previous machine.<br />
OUTPUT<br />
It is possible that the STR is connected to a next machine with a 15Sub-D cable.<br />
Through this cable, the STR transmit the communication between the machine after the STR to the machine<br />
in front of the STR.<br />
Signal name Direction Purpose<br />
Alternate Interface<br />
Ready / Not ready<br />
From previous machine -> next<br />
machine.<br />
To give the status from the machine<br />
after the STR to the machine in front.
3. Global functionality description<br />
Bypass mode: Trimming mode:<br />
The Bypass mode transports the booklet from the<br />
infeed inside the 2-Side Trimmer, aligns the booklet,<br />
and transport it to the outfeed.<br />
Go to Bypass mode by continue chapter:<br />
3.1 Bypass mode<br />
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The Trimming mode transports the booklet from the<br />
infeed inside the 2-Side Trimmer, aligns the booklet,<br />
trimmes the top and bottom side of booklet, and<br />
transport it to the outfeed.<br />
Go to Trimming mode by continue chapter:<br />
3.2 Trimming mode<br />
On the following pages both operating modes are explained in more detailed steps.
3. Global functionality description (<strong>continued</strong>)<br />
3.1 Bypass mode<br />
I) A booklet is sent from the previous machine.<br />
With every booklet that leaves the previous machine a ‘start’<br />
signal is sent to the STR, the belt propulsion motor (Motor5)<br />
starts.<br />
When FC4 or FC7 are active, the STR will give an error<br />
STR107. Empty the Trim Waste Bin.<br />
When the booklet arrives inside the STR it will be<br />
transported to the output side up to the Paper-stop.<br />
II) The infeed sensor (FC3) is active.<br />
The time between the ‘start’ signal and sensor (FC3)<br />
activation should be less than 1 second, after that the<br />
STR will give an error STR101.<br />
To check if the booklet has arrived in the STR correctly.<br />
III) The infeed sensor (FC3) is inactive.<br />
Sensor (FC3) activation should be less than 1 second,<br />
after that the STR will give an error STR102.<br />
To check that the booklet have transported into the STR.<br />
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FC3<br />
FC3<br />
Contents<br />
�<br />
Motor5
3. Global functionality description (<strong>continued</strong>)<br />
3.1 Bypass mode (<strong>continued</strong>)<br />
IV) When the booklet arrived at the Paper-stop, sensor (FC2) is<br />
active and the belt propulsion motor (Motor5) stops.<br />
The time between sensor FC3 and FC2 should be less<br />
than 3 seconds, after that the STR will give an error STR103.<br />
To check if the booklet has arrived at the Paper-stop<br />
correctly.<br />
V) The Side Joggers start to move (Motor7 and Motor8) and<br />
deactivates Switch S11 and Switch S13.<br />
The Side Joggers aligning the booklet.<br />
VI) When the Side Joggers are reaching the absolute position<br />
(adjusted Side Trim size) the Side Joggers will stop.<br />
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FC3<br />
FC2<br />
Contents<br />
�<br />
Motor5<br />
� S11<br />
Motor8<br />
�<br />
Motor8<br />
S13<br />
�<br />
Motor7<br />
�<br />
Motor7
3. Global functionality description (<strong>continued</strong>)<br />
3.1 Bypass mode (<strong>continued</strong>)<br />
VII) Both Side Joggers return to their ‘home position’.<br />
VIII) When S11 and S13 are activated, Motor7 and Motor8 stops.<br />
IX) The solenoid M1 will be activated and the Paper-stop is<br />
going down.<br />
The belt propulsion motor (Motor5) starts.<br />
The booklet is transported to the output side of the STR.<br />
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�<br />
Motor8<br />
Contents<br />
S13<br />
� S11<br />
Motor8<br />
M1<br />
�<br />
Motor7<br />
�<br />
Motor7<br />
�<br />
Motor5
3. Global functionality description (<strong>continued</strong>)<br />
3.1 Bypass mode (<strong>continued</strong>)<br />
X) Sensor FC2 is inactive.<br />
Sensor FC2 activation should be less than 2 seconds,<br />
after that the STR will give an error STR104.<br />
To check if the booklet was transported from the Paper-stop<br />
to the outfeed.<br />
Solenoid M1 is deactivated and the Paper-stop is closing.<br />
XI) Outfeed Sensor FC1 is active.<br />
The time between sensor FC2 and FC1 should be less than 1<br />
second, after that the STR will give an error STR105.<br />
To check if the booklet has arrived at the outfeed correctly.<br />
XII) Sensor FC1 is inactive.<br />
The time when FC1 is activated should be less than 2<br />
seconds, after that the STR will give an error STR106.<br />
To check if the booklet was transported out of the STR<br />
correctly.<br />
The belt propulsion motor (Motor5) stops.<br />
The booklet is transported out of the STR.<br />
3 Global functionality description (<strong>continued</strong>)<br />
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FC2<br />
FC2<br />
FC1<br />
FC1<br />
M1<br />
Contents<br />
�<br />
Motor5<br />
Contents<br />
�<br />
Motor5
3.2 Trimming mode<br />
I) A booklet is sent from the previous machine.<br />
With every booklet that leaves the previous machine a ‘start’<br />
signal is sent to the STR, the belt propulsion motor (Motor5)<br />
starts.<br />
When FC4 or FC7 are active, the STR will give an error<br />
STR107. Empty the Trim Waste Bin.<br />
When the booklet arrives inside the STR it will be<br />
transported to the output side up to the Paper-stop.<br />
II) The infeed sensor (FC3) is active.<br />
The time between the ‘start’ signal and sensor (FC3)<br />
activation should be less than 1 second, after that the<br />
STR will give an error STR101.<br />
To check if the booklet has arrived in the STR correctly.<br />
III) The infeed sensor (FC3) is inactive.<br />
Sensor (FC3) activation should be less than 1 second,<br />
after that the STR will give an error STR102.<br />
To check that the booklet have transported into the STR.<br />
Booklet is checked on thickness (FC6).<br />
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FC3<br />
FC3<br />
FC6<br />
�<br />
Motor5
3. Global functionality description (<strong>continued</strong>)<br />
3.2 Trimming mode (<strong>continued</strong>)<br />
IV) When the booklet arrived at the Paper-stop, sensor (FC2) is<br />
active and the belt propulsion motor (Motor5) stops.<br />
The time between sensor FC3 and FC2 should be less<br />
than 3 seconds, after that the STR will give an error STR103.<br />
To check if the booklet has arrived at the Paper-stop<br />
correctly.<br />
When booklet is to thick it will aboard the trimming mode.<br />
V) The Side Joggers start to move (Motor7 and Motor8) and<br />
deactivates Switch S11 and Switch S13.<br />
The Side Joggers aligning the booklet.<br />
VI) When the Side Joggers are reaching the absolute position<br />
(adjusted Side Trim size) the Side Joggers will stop.<br />
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FC3<br />
FC2<br />
Contents<br />
�<br />
Motor5<br />
� S11<br />
Motor8<br />
�<br />
Motor8<br />
S13<br />
�<br />
Motor7<br />
�<br />
Motor7
3. Global functionality description (<strong>continued</strong>)<br />
3.2 Trimming mode (<strong>continued</strong>)<br />
VII) Both Side Joggers return to their ‘home position’.<br />
VIII) When S11 and S13 are activated, Motor7 and Motor8<br />
stop.<br />
IX) The knife motors (Motor 1, 2, 3 and 4) will be activated, the<br />
booklet is trimmed to the desired ‘Finished Size’.<br />
Knife home switch S10 and S12 are deactivated.<br />
The counter (CNT1) adds 1 Trim-cycle to the total.<br />
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�<br />
3 Global functionality description (<strong>continued</strong>)<br />
FC4<br />
�<br />
Motor8<br />
CNT<br />
0001<br />
�<br />
Motor3<br />
�<br />
Contents<br />
� S11<br />
Motor8<br />
Motor1<br />
FC7<br />
Motor2<br />
�<br />
Motor7<br />
S13<br />
�<br />
Motor7<br />
�<br />
Motor4<br />
Contents<br />
S10<br />
S12
3.2 Trimming mode (<strong>continued</strong>)<br />
X) The cutting waste falls down into the Trim waste bin.<br />
Sensor Waste drawer full FC4 and FC7 detects for a very<br />
short time (< 1sec.) the cutting waste when it falls down.<br />
The short time is used to check if the cutting waste actually<br />
falls down in the Trim waste bin.<br />
Sensor Waste drawer full FC4 or FC7 activation should be<br />
less than 5 seconds for more than 10 booklets, after that the<br />
STR will give an error STR107.<br />
Empty the Trim Waste Bin.<br />
XI) When the knife home switches S10 and S12 are activated the<br />
knife motors will be deactivated.<br />
XII) Solenoid M1 will be activated and the Paper-stop is going<br />
down.<br />
The belt propulsion motor (Motor5) starts.<br />
The booklet is transported to the output side of the STR.<br />
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FC4<br />
FC7<br />
� �<br />
�<br />
Motor1<br />
FC4<br />
FC7<br />
Motor3<br />
M1<br />
Motor2<br />
�<br />
Motor4<br />
S10<br />
S12<br />
�<br />
Motor5
3. Global functionality description (<strong>continued</strong>)<br />
3.2 Trimming mode (<strong>continued</strong>)<br />
XIII) Sensor FC2 is inactive.<br />
Sensor FC2 activation should be less than 2 seconds,<br />
after that the STR will give an error STR104.<br />
To check if the booklet was transported from the Paper-stop<br />
to the outfeed.<br />
Solenoid M1 is deactivated and the Paper-stop is closing.<br />
XIV) Outfeed Sensor FC1 is active.<br />
The time between sensor FC2 and FC1 should be less than 1<br />
second, after that the STR will give an error STR105.<br />
To check if the booklet has arrived at the outfeed correctly.<br />
XV) Sensor FC1 is inactive.<br />
The time when FC1 is activated should be less than 2<br />
seconds, after that the STR will give an error STR106.<br />
To check if the booklet was transported out of the STR<br />
correctly.<br />
The belt propulsion motor (Motor5) stops.<br />
The booklet is transported out of the STR.<br />
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FC2<br />
FC2<br />
FC1<br />
FC1<br />
M1<br />
Contents<br />
�<br />
Motor5<br />
�<br />
Motor5
4. Covers<br />
4.1 Front Cover<br />
Fig. 4.1 Fig. 4.2<br />
Fig. 4.3 Fig. 4.4<br />
Removal<br />
No. Action Remarks<br />
1 Open the Top cover. (See Fig. 4.1)<br />
2 Switch off the main power switch and disconnect the power cord.<br />
3 Remove Screw (A) (See Fig. 4.2)<br />
4 Lift the Front cover upwards to unhook the cover at the lower end. (See Fig. 4.3 & 4.4)<br />
5 Disconnect the Ground wire<br />
6 Remove the Front cover<br />
Installation<br />
No. Action Remarks<br />
1 For installation follow the Removal procedure in reversed order.<br />
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Contents<br />
A
4. Covers (<strong>continued</strong>)<br />
4.2 Rear Cover<br />
Fig. 4.5 Fig. 4.6<br />
Fig. 4.7 Fig. 4.8<br />
Removal<br />
No. Action Remarks<br />
1 Open the Top cover. (See Fig. 4.5)<br />
2 Switch off the main power switch and disconnect the power cord.<br />
3 Remove Screw (A) (See Fig. 4.6)<br />
4 Close the Top cover.<br />
5 Lift Rear cover upwards to unhook the cover at the lower end. (See Fig. 4.7 & 4.8)<br />
6 Disconnect the Ground wire<br />
7 Remove the Rear cover<br />
Installation<br />
No. Action Remarks<br />
1 For installation follow the Removal procedure in reversed order.<br />
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A<br />
Contents
4. Covers (<strong>continued</strong>)<br />
4.3 Upper Infeed Cover<br />
Fig. 4.9<br />
A<br />
Fig. 4.10 Fig. 4.11<br />
Removal<br />
No. Action Remarks<br />
1 Remove the Front & Rear Cover (See Chap. 4.1 & 4.2)<br />
2 Switch off the main power switch and disconnect the power cord.<br />
3 Remove Screws [A] & [B] on both sides of the STR (See Fig. 4.10 & 4.11)<br />
4 Remove the Upper Infeed cover from the machine. (See Fig. 4.9)<br />
Installation<br />
No. Action Remarks<br />
1 For installation follow the Removal procedure in reversed order.<br />
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B<br />
Contents
4. Covers (<strong>continued</strong>)<br />
4.4 Lower Infeed Cover<br />
Fig. 4.12<br />
C<br />
Fig. 4.13 Fig. 4.14<br />
Removal<br />
No. Action Remarks<br />
1 Remove the Front & Rear Cover (See Chap. 4.1 & 4.2)<br />
2 Switch off the main power switch and disconnect the power cord.<br />
3 Remove Screws [C] & [D] on both sides of the STR (See Fig. 4.13 & 4.14)<br />
4 Remove the Lower Infeed cover from the machine. (See Fig. 4.12)<br />
Installation<br />
No. Action Remarks<br />
1 For installation follow the Removal procedure in reversed order.<br />
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D<br />
Contents
4. Covers (<strong>continued</strong>)<br />
4.5 Upper Outfeed Cover<br />
Fig. 4.15<br />
E F<br />
Fig. 4.16 Fig. 4.17<br />
Removal<br />
No. Action Remarks<br />
1 Remove the Front & Rear Cover (See Chap. 4.1 & 4.2)<br />
2 Switch off the main power switch and disconnect the power cord.<br />
3 Remove Screws [E] & [F] on both sides of the STR (See Fig. 4.16 & 4.17)<br />
4 Remove the Upper Outfeed cover from the machine. (See Fig. 4.15)<br />
Installation<br />
No. Action Remarks<br />
1 For installation follow the Removal procedure in reversed order.<br />
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4. Covers (<strong>continued</strong>)<br />
4.6 Lower Outfeed Cover<br />
Fig. 4.18<br />
G H<br />
Fig. 4.19 Fig. 4.20<br />
Removal<br />
No. Action Remarks<br />
1 Remove the Front & Rear Cover (See Chap. 4.1 & 4.2)<br />
2 Switch off the main power switch and disconnect the power cord.<br />
3 Remove Screws [G] & [H] on both sides of the STR (See Fig. 4.19 & 4.20)<br />
4 Remove the Lower Outfeed cover from the machine. (See Fig. 4.18)<br />
Installation<br />
No. Action Remarks<br />
1 For installation follow the Removal procedure in reversed order.<br />
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4. Covers (<strong>continued</strong>)<br />
4.7 Base Plate Cover<br />
J<br />
K<br />
Fig. 4.21 Fig 4.22<br />
Removal<br />
No. Action Remarks<br />
1 Switch off the main power switch and disconnect the power cord.<br />
2 Remove Screws [J] & [K] on the back of Base STR (See Fig. 4.21)<br />
3 Remove Base Plate cover from the machine. (See Fig. 4.22)<br />
Installation<br />
No. Action Remarks<br />
1 For installation follow the Removal procedure in reversed order.<br />
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4. Covers (<strong>continued</strong>)<br />
4.8 User Interface Cover<br />
L<br />
M<br />
Fig. 4.23 Fig 4.24<br />
Removal<br />
No. Action Remarks<br />
1 Switch off the main power switch and disconnect the power cord.<br />
2 Remove Screws [L] & [M] on the back of the User Interface (See Fig. 4.23)<br />
3 Remove User Interface cover from the machine. (See Fig. 4.24)<br />
Installation<br />
No. Action Remarks<br />
1 For installation follow the Removal procedure in reversed order.<br />
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5. Troubleshooting<br />
5.1 Service Program mode<br />
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The Service Program mode (SP) can be used to check electrical data, electrical components and adjust<br />
values. This Service Program mode is provided and controlled by the UI (User Interface) on the STR or<br />
Booklet Maker. Peripheral units are embedded in this service program. Where applicable, a sub menu<br />
appears after a function is selected listing the peripherals.<br />
Entering and Exiting the SP mode<br />
There are two ways to enter the Service Program mode either from the operator mode [1] or directly from<br />
switched off machine [2].<br />
Fig. 5.1 Fig. 5.2<br />
Fig. 5.3 Fig. 5.4<br />
[1]<br />
No. Action<br />
1 Press the ‘Admin’ button. (Note: Insert the Interlock cheater, otherwise some functions do not work!)<br />
2 Use the ‘▲ / ▼ buttons’ to select ‘Service’ and press the ‘Enter’ button.<br />
3 Enter the standard access code: 1974 or 1983 (by using the ‘◄ / ►’ and ‘+ / -‘ buttons) and press<br />
the ‘Enter’ button.<br />
4 Use the ‘▲ / ▼ buttons’ to select the Target that need to be checked and press the ‘Enter’ button.<br />
5 Press the ‘ ’ button to exit the Service Program mode and enter the Operator mode.<br />
[2]<br />
No. Action<br />
1 Press and hold the lower button on the UI.<br />
2 Switch on the main Power Switch.<br />
3 Release the lower button on the UI after the Service Access Code menu appears.<br />
4 Enter the access code: 1974 or 1983 (by using the ‘◄ / ►’ and ‘+ / -‘ buttons) and press the ‘Enter’<br />
button.<br />
5 Use the ‘▲ / ▼ buttons’ to select the Target that need to be checked and press the ‘Enter’ button.<br />
6 Press the ‘ ’ button to exit the Service Program mode and enter the Operator mode.
5. Troubleshooting (<strong>continued</strong>)<br />
5.1 Service program mode (<strong>continued</strong>)<br />
5.1.1 Software Version<br />
Fig. 5.5 Fig. 5.6<br />
No. Action<br />
1 Enter the Service Program mode [see Chapter 5.1]<br />
2 Use the ‘▲ / ▼ buttons’ to select ‘Software version’ and press the ‘Enter’ button.<br />
3 Check the Software version of the CPU(PCB6), MD6DC(PCB1) and MD6DC(PCB5).<br />
4 Press the ‘ ’ button to exit the Service Program mode and enter the Operator mode.<br />
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5. Troubleshooting (<strong>continued</strong>)<br />
5.1 Service program mode (<strong>continued</strong>)<br />
5.1.2 Diagnostics<br />
Throughout the diagnostics operation of the machine all functions and<br />
components are monitored. Should an error occur, a fault code is<br />
displayed (see Fig. 5.7). With a text message, such as<br />
”ST_MOTOR1_OPEN_CIRCUIT” many faults can simply be corrected by<br />
the Service engineer. If the text message ”Malfunction” is displayed, the<br />
fault can also be corrected by the Service engineer but requires more<br />
service research. All messages regardless of nature are always connected<br />
with a fault code.<br />
The main self-diagnostic mode, Diagnostics checks the voltages, the<br />
sensors, solenoids and the motors. If a fault is found it will be displayed<br />
as a fault code. This manual lists all fault codes. To correct the fault,<br />
go to chapter: 5.2 Fault Code Descriptions.<br />
NOTE: It is normal to receive the code ‘Fault Code 00034’ [STR034] if<br />
no Stacker is connected to the STR.<br />
Fig. 5.8 Fig. 5.9<br />
No. Action<br />
1 Enter the Service Program mode [see Chapter 5.1]<br />
2 Use the ‘▲ / ▼’ buttons to select ‘Diagnostics’ and press the ‘Enter’ button.<br />
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Contents<br />
3 Press the ‘Start’ button to start the self diagnostic mode and press ‘Stop’ to end the self diagnostic<br />
mode.<br />
4 Press the ‘ ’ button to exit the Service Program mode and enter the Operator mode.<br />
Fig. 5.7
5. Troubleshooting (<strong>continued</strong>)<br />
5.1 Service program mode (<strong>continued</strong>)<br />
5.1.3 Motors<br />
To check if the motors are functioning correctly by operating them separately.<br />
Always ‘Unlock’ the selected Motor before changing the status of functionality.<br />
Functionality: CW = moving in (clockwise)<br />
CCW = moving out (counter clockwise)<br />
Cycle 1 = moving 1 complete cycle<br />
Attention: Do not use ‘CW’ or ‘CCW’ more than 1 time!!!<br />
Fig. 5.10 Fig. 5.11<br />
Fig. 5.12 Fig. 5.13<br />
No. Action<br />
1 Enter the Service Program mode [see Chapter 5.1]<br />
2 Use the ‘▲ / ▼’ buttons to select ‘Motors’ and press the ‘Enter’ button (Fig. 5.10).<br />
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3 Use the ‘▲ / ▼’ buttons to select the Motor that need to be checked and press the ‘Enter’ button<br />
(Fig. 5.11).<br />
4 For Knife-motors only press the ‘Unlock’ button to change the status of the Motor (Fig. 5.12).<br />
5 Press the ‘CW / CCW / Cycle 1’ buttons to check the functionality of the selected Motor (differs per<br />
motor)<br />
6 After checking press the ‘OFF’ buttons to change the Status of the Motor back in the ‘normal’<br />
situation.<br />
7 Press the ‘ ’ button to exit the Service Program mode and enter the Operator mode.
5. Troubleshooting (<strong>continued</strong>)<br />
5.1 Service program mode (<strong>continued</strong>)<br />
5.1.4 Solenoids<br />
To check if the Solenoid(s) are functioning correctly.<br />
Fig. 5.15 Fig. 5.16<br />
Fig. 5.17<br />
No. Action<br />
1 Enter the Service Program mode [see Chapter 5.1]<br />
2 Use the ‘▲ / ▼’ buttons to select ‘Solenoids’ and press the ‘Enter’ button.<br />
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3 Use the ‘▲ / ▼’ buttons to select the Solenoid that need to be checked and press the ‘Enter’ button.<br />
4 Press the ‘ON / OFF’ buttons to check the functionality of the selected Solenoid.<br />
5 After checking press the ‘OFF’ buttons to change the Status of the Solenoid back in the ‘normal’<br />
situation.<br />
6 Press the ‘ ’ button to exit the Service Program mode and enter the Operator mode.
5. Troubleshooting (<strong>continued</strong>)<br />
5.1 Service program mode (<strong>continued</strong>)<br />
5.1.5 Sensors and Switches<br />
To check if the Sensors and Switches are functioning correctly.<br />
Fig. 5.18 Fig. 5.19<br />
Fig. 5.20<br />
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Contents<br />
All sensors and switches can individually be checked by blocking/unblocking sensors.<br />
While blocking/unblocking, view the display for response. Displayed is the state by :0 / ’Low’ (unblocked / not<br />
activated) :1 / ’High’ (= blocked / activated).<br />
Which state corresponding to blocked/unblocked is depending on whether the sensor or switch has inverted<br />
function or not. For status definition, see Service Program Mode Tables 5.1.2.<br />
No. Action<br />
1 Enter the Service Program mode [see Chapter 5.1]<br />
2 Use the ‘▲ / ▼’ buttons to select ‘Sensors’ and press the ‘Enter’ button.<br />
3 Use the ‘▲ / ▼’ buttons to select the Sensor or Switch that need to be checked and press the ‘Enter’<br />
button.<br />
Pay attention! In the Sensors menu there are more pages available.<br />
Use the ‘Next’ button to view the other pages.<br />
4 Check the Value : When :0/‘Low’ the sensor is not activated, when :1/‘High’ the sensor is activated.<br />
5 Press the ‘ ’ button to exit the Service Program mode and enter the Operator mode.
5. Troubleshooting (<strong>continued</strong>)<br />
5.1 Service program mode (<strong>continued</strong>)<br />
5.1.6 Voltmeters<br />
To check if the Electrical boards (prints) have the right voltage.<br />
Fig. 5.21 Fig. 5.22<br />
Fig. 5.23<br />
No. Action<br />
1 Enter the Service Program mode [see Chapter 5.1]<br />
2 Use the ‘▲ / ▼’ buttons to select ‘Voltmeters’ and press the ‘Enter’ button.<br />
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3 Use the ‘▲ / ▼’ buttons to select the Voltmeter that need to be checked and press the ‘Enter’ button.<br />
4 Check the Value.<br />
5 Press the ‘ ’ button to exit the Service Program mode and enter the Operator mode.<br />
Voltage at Analogue<br />
Value<br />
Unregulated In 23-43V Unregulated 36V(before interlock PCB3) from Power supply in STR measured<br />
on Interlock PCB3<br />
Unregulated Out 23-43V Unregulated 36V(after interlock PCB3 before K1) measured on Interlock PCB3<br />
24V 16-30V Regulated 24V distributed from interlock PCB measured on Interlock PCB3<br />
Unregulated PCB1 23-43V Unregulated 36V (after interlock PCB3, after K1) measured on PCB1.<br />
Voltage supplies: M1 Knife 1<br />
M2 Knife 1<br />
M5 Int Transport<br />
M7 Side Jogger<br />
M Stacker<br />
Unregulated PCB5 23-43V Unregulated 36V (after interlock PCB3, after K1) measured on PCB5.<br />
Voltage supplies: M3 Knife 2<br />
M4 Knife 2<br />
M6 Width adjust<br />
M8 Side Jogger
5. Troubleshooting (<strong>continued</strong>)<br />
5.1 Service program mode (<strong>continued</strong>)<br />
5.1.7 Non Volatile Memory (NVM)<br />
NVM values (non volatile memory) are different address locations within the EE-prom.<br />
Each address reflects timing,calibration,counter or function in the system.<br />
Fig. 5.24 Fig. 25<br />
Fig. 5.26<br />
No. Action<br />
1 Enter the Service Program mode [see Chapter 5.1]<br />
2 Use the ‘▲ / ▼’ buttons to select ‘NVM’ and press the ‘Enter’ button.<br />
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3 Use the ‘▲ / ▼’ buttons to select the NVM setting that need to be checked or changed and press the<br />
‘ ’ or ‘Change’ button.<br />
4 Use the ‘+ / -‘ buttons to set a NewValue(Dec) and press the ‘OK’ button.<br />
5 Press the ‘ESC’ or ‘ ’ button to exit the Service Program mode and enter the Operator mode.
5. Troubleshooting (<strong>continued</strong>)<br />
5.1 Service program mode (<strong>continued</strong>)<br />
5.1.8 Dead cycle<br />
To make one complete Trim cycle.<br />
Dead cycling is a modified machine cycle. All functions in the machine are run such<br />
as motors and solenoids. The program is basically made for factory testing, but can<br />
be of some use when trouble shooting.<br />
Fig. 5.27 Fig. 5.28<br />
No. Action<br />
1 Enter the Service Program mode [see Chapter 5.1]<br />
2 Use the ‘▲ / ▼’ buttons to select ‘Dead cycle’ and press the ‘Enter’ button.<br />
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3 Use the ‘Start’ button to select the start the Dead cycle and the ‘Stop’ button to end the Dead cycle.<br />
4 Press the ‘ESC’ or ‘ ’ button to exit the Service Program mode and enter the Operator mode.
5. Troubleshooting (<strong>continued</strong>)<br />
5.1 Service program mode (<strong>continued</strong>)<br />
5.1.9 Calibration<br />
Can be used for adjusting the Side Jogger correction.<br />
See chapter 8.2.2 NVM Side Jogger correction.<br />
Fig. 5.29<br />
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5. Troubleshooting (<strong>continued</strong>)<br />
5.2 Fault Code Descriptions<br />
Before continue using the Fault Code Descriptions please make sure that all connectors are<br />
connected.<br />
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Fault Item Fault Description Page<br />
code No. No.<br />
STR 001 STR M1 Motor1 Cycle Timeout 49<br />
STR 002 STR M1 Motor1 Short Circuit 49<br />
STR 003 STR M1 Motor1 Open Circuit 49<br />
STR 004 STR M2 Motor2 Cycle Timeout 50<br />
STR 005 STR M2 Motor2 Short Circuit 51<br />
STR 006 STR M2 Motor2 Open Circuit 52<br />
STR 007 STR M3 Motor3 Cycle Timeout 52<br />
STR 008 STR M3 Motor3 Short Circuit 52<br />
STR 009 STR M3 Motor3 Open Circuit 53<br />
STR 010 STR M4 Motor4 Cycle Timeout 53<br />
STR 011 STR M4 Motor4 Short Circuit 54<br />
STR 012 STR M4 Motor4 Open Circuit 54<br />
STR 013 STR M5 Motor5 Pulse Timeout 55<br />
STR 014 STR M5 Motor5 Cycle Timeout 55<br />
STR 015 STR M5 Motor5 Short Circuit 55<br />
STR 016 STR M5 Motor5 Open Circuit 56<br />
STR 017 STR M6 Motor6 Pulse Timeout 56<br />
STR 018 STR M6 Motor6 Cycle Timeout 56<br />
STR 019 STR M6 Motor6 Short Circuit 57<br />
STR 020 STR M6 Motor6 Open Circuit 57<br />
STR 021 STR M7 Motor7 Pulse Timeout 58<br />
STR 022 STR M7 Motor7 Cycle Timeout 58<br />
STR 023 STR M7 Motor7 Short Circuit 59<br />
STR 024 STR M7 Motor7 Open Circuit 59<br />
STR 025 STR M8 Motor8 Pulse Timeout 60<br />
STR 026 STR M8 Motor8 Cycle Timeout 60<br />
STR 027 STR M8 Motor8 Short Circuit 61<br />
STR 028 STR M8 Motor8 Open Circuit 61<br />
STR 029 STR MAG1 Magnet1 Open Circuit 62<br />
STR 030 STR MAG1 Magnet1 Short Circuit 63<br />
STR 032 ST M1 Stacker Motor1 Open Circuit 63<br />
STR 033 ST M1 Stacker Motor1 Short Circuit 64<br />
STR 041 STR JOG1 Jogger1 Not Home 64<br />
STR 042 STR JOG2 Jogger2 Not Home 65<br />
STR 043 STR M6 Motor6 Home to high 65<br />
STR 045 STR PCB1 No response from MD6DC PCB1 66<br />
STR 046 STR PCB5 No response from MD6DC PCB5 67
5. Troubleshooting (<strong>continued</strong>)<br />
5.2 Fault Code Descriptions (<strong>continued</strong>)<br />
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STR 051 STR FC1 FC1 Faulty 68<br />
STR 052 STR FC2 FC2 Faulty 68<br />
STR 053 STR FC3 FC3 Faulty 69<br />
STR 054 STR FC4 FC4 or FC7 Faulty 69<br />
STR 055 STR ENC5 ENC5 Faulty 70<br />
STR 056 STR ENC6 ENC6 Faulty 70<br />
STR 057 STR ENC7 ENC7 Faulty 70<br />
STR 058 STR ENC8 ENC8 Faulty 70<br />
STR 059 STR FC6 FC6 Faulty 70<br />
STR 061 STR S1 S1 Faulty 71<br />
STR 062 STR S2 S2 Faulty 71<br />
STR 063 STR K2 Interlock Circuit Faulty 71<br />
STR 064 STR S3,4,7,8 S3 S4 S7 S8 or K2 Faulty 72<br />
STR 065 STR S9 S9 Faulty 72<br />
STR 066 STR S10 S10 Faulty 73<br />
STR 067 STR S11 S11 Faulty 73<br />
STR 068 STR S12 S12 Faulty 73<br />
STR 069 STR S13 S13 Faulty 74<br />
STR 070 STR S19 S19 Faulty 74<br />
STR 071 STR S18 S18 Faulty 74<br />
STR 080 36V INPUT 36V input Low 75<br />
STR 081 36V INPUT 36V input High 76<br />
STR 082 36V OUTPUT 36V output Low 76<br />
STR 083 36V OUTPUT 36V output High 76<br />
STR 084 24V OUTPUT 24V Low 76<br />
STR 085 24V OUTPUT 24V High 76<br />
STR 086 36V M6DC1 36V M6DC PCB1 Low 76<br />
STR 087 36V M6DC1 36V M6DC PCB1 High 77<br />
STR 088 36V M6DC5 36V M6DC PCB5 Low 77<br />
STR 089 36V M6DC5 36V M6DC PCB5 High 77<br />
STR 101 JAM FC3 Not Covered 78<br />
STR 102 JAM FC3 Not Uncovered 78<br />
STR 103 JAM FC2 Not Covered 78<br />
STR 104 JAM FC2 Not Uncovered 78<br />
STR 105 JAM FC1 Not Covered 79<br />
STR 106 JAM FC1 Not Uncovered 79<br />
STR 107 JAM FC4 or FC7 Trim Waste Bin Full 79
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions<br />
Before continue using the Fault Code Descriptions please make sure that all connectors are<br />
connected.<br />
STR 001 Motor1 Cycle Timeout<br />
• See STR 004 Motor2 Cycle Timeout<br />
STR 002 Motor1 Short Circuit<br />
Procedure<br />
Disconnect the Motor plug M1. Run the diagnostics. Fault code STR 003(Open Circuit) is displayed?<br />
Y N<br />
Disconnect connector J6. Check wires for Short Circuit across leads. (Red1 & Black8)<br />
Is there a short Circuit?<br />
Y N<br />
Disconnect plug 1P3 from PCB1. Check wires for Short Circuit across leads. (Red2 & Black3)<br />
Is there a Short Circuit?<br />
Y N<br />
Replace PCB1<br />
Replace wire harness<br />
Replace wire harness<br />
Replace motor STR-M1<br />
STR 003 Motor1 Open Circuit<br />
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Procedure<br />
Disconnect the motor plug M1. Enter service mode, unlock and start the Motor M1. Measure between the Red and Black wire. The<br />
voltage is approximately 12VDC?<br />
Y N<br />
Disconnect connector J6 and cycle Motor M1. Measure between the Red and Black wire. (Red1&Black8). The voltage is<br />
approximately 12VDC?<br />
Y N<br />
Disconnect plug 1P3 from PCB1 and cycle Motor M1. Measure between points 2 and 3.<br />
The voltage is approximately 12VDC?<br />
Y N<br />
Replace PCB1<br />
Replace wire harness<br />
Replace wire harness<br />
Replace Motor M1
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 004 Motor2 Cycle Timeout<br />
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Procedure<br />
Enter the Service mode and select Trimmer Knife home position (STR S10) in Switches. The switch indicates: 1 when activated,<br />
and: 2 when not activated?<br />
Y N<br />
Go to STR 066 – S10 Faulty<br />
Disconnect Motor2 (STR M2), enter the Service mode and select Motor1 (STR M1) in motors, unlock and start Motor1 (STR M1) The<br />
motor energizes?<br />
Y N<br />
Go to STR 003 – Motor 1 Open Circuit<br />
Connect Motor2 (STR M2) Disconnect Motor1 (STR M1), enter the Service mode and select Motor2 (STR M2) in motors, unlock and<br />
start Motor2 (STR M2) The motor energizes?<br />
Y N<br />
Go to STR 006 – Motor 2 Open Circuit<br />
1. Make sure that nothing interferes with the mechanical movement.<br />
2. Lubricate where needed.
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 005 Motor2 Short Circuit<br />
Procedure<br />
Disconnect the Motor plug M2. Run the diagnostics. Fault code STR 005(Short Circuit) is displayed?<br />
Y N<br />
Replace motor STR-M2.<br />
Disconnect J-CNT1. Run the diagnostics. Fault code STR 006(Open Circuit) is displayed?<br />
Y N<br />
Disconnect connector J6. Check wires for Short Circuit across leads. (Red2 & Black9)<br />
Is there a short Circuit?<br />
Y N<br />
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Disconnect plug 1P3 from PCB1 Check wires for Short Circuit across leads. (Red6 & Black7) Is there a Short<br />
Circuit?<br />
Y N<br />
Disconnect connector J8. Check wires for Short Circuit across leads. (Orange3 & Violet6) Is there a<br />
Short Circuit?<br />
Y N<br />
Disconnect connector J9. Check wires for Short Circuit across leads. (Orange3 & Violet6) Is<br />
there a Short Circuit?<br />
Y N<br />
Check connector 1P3 wires for Short circuit across leads. (Orange5 & Violet8) Is there<br />
a Short Circuit?<br />
Y N<br />
Replace STR-PCB1<br />
Replace wire harness<br />
Replace wire harness<br />
Replace wire harness<br />
Replace wire harness<br />
Replace wire harness<br />
Replace Counter STR-CNT1
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 006 Motor2 Open Circuit<br />
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Procedure<br />
Disconnect the motor plug M2. Enter service mode, unlock and cycle the Motor M2. Measure between the Red and Black wire. The<br />
voltage is approximately 22VDC?<br />
Y N<br />
Disconnect connector J6 and cycle Motor M2. Measure between the Red and Black wire. (Red2&Black9). The voltage is<br />
approximately 22VDC?<br />
Y N<br />
Disconnect plug 1P3 from PCB1 and cycle Motor M2. Measure between points 6 and 7.<br />
The voltage is approximately 22VDC?<br />
Y N<br />
Replace PCB1<br />
Replace wire harness<br />
Replace wire harness<br />
Replace Motor M2<br />
STR 007 Motor3 Cycle Timeout<br />
• See STR 010 Motor4 Cycle Timeout<br />
STR 008 Motor3 Short Circuit<br />
Procedure<br />
Disconnect the Motor plug M3. Run the diagnostics. Fault code STR 009(Open Circuit) is displayed?<br />
Y N<br />
Disconnect connector J7. Check wires for Short Circuit across leads. (Red1 & Black8)<br />
Is there a short Circuit?<br />
Y N<br />
Disconnect plug 5P3 from PCB5 Check wires for Short Circuit across leads. (Red2 & Black3)<br />
Is there a Short Circuit?<br />
Y N<br />
Replace PCB5<br />
Replace wire harness<br />
Replace wire harness<br />
Replace motor STR-M3
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 009 Motor3 Open Circuit<br />
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Procedure<br />
Disconnect the motor plug M3. Enter service mode, unlock and start the Motor M3. Measure between the Red and Black wire. The<br />
voltage is approximately 12VDC?<br />
Y N<br />
Disconnect connector J7 and cycle Motor M3. Measure between the Red and Black wire. (Red1&Black8). The voltage is<br />
approximately 12VDC?<br />
Y N<br />
Disconnect plug 5P3 from PCB1 and cycle Motor M3. Measure between points 2 and 3.<br />
The voltage is approximately 12VDC?<br />
Y N<br />
Replace PCB5<br />
Replace wire harness<br />
Replace wire harness<br />
Replace Motor M3<br />
STR 010 Motor4 Cycle Timeout<br />
Procedure<br />
Enter the Service mode and select Trimmer Knife home position (STR S12) in Switches. The switch indicates: 1 when activated,<br />
and: 2 when not activated?<br />
Y N<br />
Go to STR 068 – S10 Faulty<br />
Disconnect Motor4 (STR M4), enter the Service mode and select Motor3 (STR M3) in motors, unlock and start Motor3 (STR M3) The<br />
motor energizes?<br />
Y N<br />
Go to STR 009 – Motor 3 Open Circuit<br />
Connect Motor4 (STR M4) Disconnect Motor3 (STR M3), enter the Service mode and select Motor4 (STR M4) in motors, unlock and<br />
start Motor4 (STR M4) The motor energizes?<br />
Y N<br />
Go to STR 012 – Motor 4 Open Circuit<br />
1. Make sure that nothing interferes with the mechanical movement.<br />
2. Lubricate where needed.
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 011 Motor4 Short Circuit<br />
Procedure<br />
Disconnect the Motor plug M3. Run the diagnostics. Fault code STR 012(Open Circuit) is displayed?<br />
Y N<br />
Disconnect connector J7. Check wires for Short Circuit across leads. (Red2 & Black9)<br />
Is there a short Circuit?<br />
Y N<br />
Disconnect plug 5P3 from PCB5 Check wires for Short Circuit across leads. (Red6 & Black7)<br />
Is there a Short Circuit?<br />
Y N<br />
Replace PCB5<br />
Replace wire harness<br />
Replace wire harness<br />
Replace motor STR-M4<br />
STR 012 Motor4 Open Circuit<br />
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Procedure<br />
Disconnect the motor plug M4. Enter service mode and cycle the Motor M4. Measure between the Red and Black wire. The voltage<br />
is approximately 22VDC?<br />
Y N<br />
Disconnect connector J7 and cycle Motor M3. Measure between the Red and Black wire. (Red2&Black9). The voltage is<br />
approximately 22VDC?<br />
Y N<br />
Disconnect plug 5P3 from PCB1 and cycle Motor M3. Measure between points 6 and 7.<br />
The voltage is approximately 22VDC?<br />
Y N<br />
Replace PCB5<br />
Replace wire harness<br />
Replace wire harness<br />
Replace Motor M4
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 013 Motor5 Pulse Timeout<br />
Procedure<br />
STR 014 Motor5 Cycle Timeout<br />
• Go to STR 016 – Motor5 Open Circuit.<br />
STR 015 Motor5 Short Circuit<br />
Procedure<br />
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Enter the Service mode and select Motor5 encoder in sensors. Slowly rotate the motor by hand and check the value on the display.<br />
Value toggles between “0” and “1”?<br />
Y N<br />
Disconnect the sensor plug to Motor5 (STR-Motor5). Measure between the two wires for the sensor (5V and Signal ground).<br />
The voltage is approximately 5VDC?<br />
Y N<br />
Replace Sensor<br />
Check wires for damage. Are the wires damaged?<br />
Y N<br />
Go to STR 015 Motor Short Circuit<br />
Replace wire Harness<br />
Enter service mode and start Motor5. The motor starts?<br />
Y N<br />
Go to STR 016 Motor 5 Open Circuit<br />
Check for obstructions<br />
Disconnect the wires from Motor M5. Run the diagnostics. Fault code STR 016(Open Circuit) is displayed?<br />
Y N<br />
Disconnect plug 1P2 from PCB1 Check wires for Short Circuit across leads. (Orange4 & Violet11)<br />
Is there a Short Circuit?<br />
Y N<br />
Replace PCB1<br />
Replace wire harness<br />
Replace motor STR-M5
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 016 Motor5 Open Circuit<br />
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Procedure<br />
Disconnect the motor plug M5. Enter service mode and cycle the Motor M5. Measure between the Orange and Violet wire. The<br />
voltage is approximately 22VDC?<br />
Y N<br />
Disconnect plug 5P3 from PCB1 and cycle Motor M3. Measure between points 6 and 7.<br />
The voltage is approximately 22VDC?<br />
Y N<br />
Replace PCB1<br />
Replace wire harness<br />
Replace Motor M5<br />
STR 017 Motor6 Pulse Timeout<br />
Procedure<br />
Enter the Service mode and select Motor6 encoder in sensors. Slowly rotate the motor by hand and check the value on the display.<br />
Value toggles between “0” and “1”?<br />
Y N<br />
Disconnect the sensor plug to Motor6 (STR-Motor6). Measure between the two wires for the sensor (5V and Signal ground).<br />
The voltage is approximately 5VDC?<br />
Y N<br />
Replace Sensor<br />
Check wires for damage. Are the wires damaged?<br />
Y N<br />
Go to STR 019 Motor6 Short Circuit<br />
Replace wire Harness<br />
Enter service mode and start Motor6. The motor starts?<br />
Y N<br />
Go to STR 020 Motor 6 Open Circuit<br />
Check for obstructions<br />
STR 018 Motor6 Cycle Timeout<br />
• Go to STR 020 – Motor6 Open Circuit
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 019 Motor6 Short Circuit<br />
Fault code STR 019 indicates that Motor6 (STR-M6) has a Short Circuit<br />
Initial Actions<br />
• Check Fuse F15 on transformer<br />
Procedure<br />
Disconnect the Motor plug M6. Run the diagnostics. Fault code STR 020(Open Circuit) is displayed?<br />
Y N<br />
Disconnect connector J5. Check wires for Short Circuit across leads. (Orange1 & Violet4)<br />
Is there a short Circuit?<br />
Y N<br />
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Disconnect plug 5P2 from PCB5 Check wires for Short Circuit across leads. (Orange4 & Violet 11) Is there a<br />
Short Circuit?<br />
Y N<br />
Replace PCB5<br />
Replace wire harness<br />
Replace wire harness<br />
Replace motor STR-M6<br />
STR 020 Motor6 Open Circuit<br />
Procedure<br />
Disconnect the motor plug M6. Enter service mode and cycle the Motor M6. Measure between the Orange and Violet wire. The<br />
voltage is approximately 22VDC?<br />
Y N<br />
Disconnect connector J5 and cycle Motor M6. Measure between the Orange and Violet wire. (Orange1&Violet4). The<br />
voltage is approximately 22VDC?<br />
Y N<br />
Disconnect plug 5P2 from PCB5 and cycle Motor M6. Measure between points 4 and 11.<br />
The voltage is approximately 22VDC?<br />
Y N<br />
Replace PCB5<br />
Replace wire harness<br />
Replace wire harness<br />
Replace Motor M6
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 021 Motor7 Pulse Timeout<br />
Procedure<br />
STR 022 Motor7 Cycle Timeout<br />
• Go to STR 024 – Motor7 Open Circuit<br />
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Warning : Fault code STR021 can be caused by a NVM 2 Infeed Position that is to high.<br />
Enter the Service mode and select Motor7 encoder A in sensors. Slowly rotate the motor by hand and check the value on the display.<br />
Value toggles between “0” and “1”?<br />
Y N<br />
Disconnect the sensor plug to Motor7 (STR-Motor7). Measure between the two wires for the sensor (5V and Signal ground).<br />
The voltage is approximately 5VDC?<br />
Y N<br />
Replace Sensor<br />
Check wires for damage. Are the wires damaged?<br />
Y N<br />
Go to STR 023 Motor 7 Short Circuit<br />
Replace wire Harness<br />
Enter the Service mode and select Motor7 encoder B in sensors. Slowly rotate the motor by hand and check the value on the display.<br />
Value toggles between “0” and “1”?<br />
Y N<br />
Disconnect the sensor plug to Motor7 (STR-Motor7). Measure between the two wires for the sensor (5V and Signal ground).<br />
The voltage is approximately 5VDC?<br />
Y N<br />
Replace Sensor<br />
Check wires for damage. Are the wires damaged?<br />
Y N<br />
Go to STR 023 Motor 7 Short Circuit<br />
Replace wire Harness<br />
Enter service mode and start Motor7. The motor starts?<br />
Y N<br />
Go to STR 024 Motor 7 Open Circuit<br />
Check for obstructions
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 023 Motor7 Short Circuit<br />
Procedure<br />
Disconnect the Motor plug M7. Run the diagnostics. Fault code STR 024(Open Circuit) is displayed?<br />
Y N<br />
Disconnect connector J6. Check wires for Short Circuit across leads. (Orange3 & Violet10)<br />
Is there a short Circuit?<br />
Y N<br />
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Disconnect plug 1P2 from PCB1 Check wires for Short Circuit across leads. (Orange2 & Violet9) Is there a Short<br />
Circuit?<br />
Y N<br />
Replace PCB1<br />
Replace wire harness<br />
Replace wire harness<br />
Replace motor STR-M7<br />
STR 024 Motor7 Open Circuit<br />
Procedure<br />
Disconnect the motor plug M7. Enter service mode and cycle the Motor M7. Measure between the Orange and Violet wire. The<br />
voltage is approximately 22VDC?<br />
Y N<br />
Disconnect connector J6 and cycle Motor M7. Measure between the Orange and Violet wire. (Orange3&Violet10). The<br />
voltage is approximately 22VDC?<br />
Y N<br />
Disconnect plug 1P2 from PCB1 and cycle Motor M7. Measure between points 2 and 9.<br />
The voltage is approximately 22VDC?<br />
Y N<br />
Replace PCB1<br />
Replace wire harness<br />
Replace wire harness<br />
Replace Motor M7
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 025 Motor8 Pulse Timeout<br />
Procedure<br />
STR 026 Motor8 Cycle Timeout<br />
• Go to STR 027 – Motor8 Open Circuit<br />
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Warning : Fault code STR025 can be caused by a NVM 4 Infeed Position that is to high.<br />
Enter the Service mode and select Motor8 encoder A in sensors. Slowly rotate the motor by hand and check the value on the display.<br />
Value toggles between “0” and “1”?<br />
Y N<br />
Disconnect the sensor plug to Motor8 (STR-Motor8). Measure between the two wires for the sensor (5V and Signal ground).<br />
The voltage is approximately 5VDC?<br />
Y N<br />
Replace Sensor<br />
Check wires for damage. Are the wires damaged?<br />
Y N<br />
Go to STR 027 Motor 8 Short Circuit<br />
Replace wire Harness<br />
Enter the Service mode and select Motor8 encoder B in sensors. Slowly rotate the motor by hand and check the value on the display.<br />
Value toggles between “0” and “1”?<br />
Y N<br />
Disconnect the sensor plug to Motor8 (STR-Motor8). Measure between the two wires for the sensor (5V and Signal ground).<br />
The voltage is approximately 5VDC?<br />
Y N<br />
Replace Sensor<br />
Check wires for damage. Are the wires damaged?<br />
Y N<br />
Go to STR 027 Motor 8 Short Circuit<br />
Replace wire Harness<br />
Enter service mode and start Motor8. The motor starts?<br />
Y N<br />
Go to STR 028 Motor 8 Open Circuit<br />
Check for obstructions
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 027 Motor8 Short Circuit<br />
Procedure<br />
Disconnect the Motor plug M8. Run the diagnostics. Fault code STR 028(Open Circuit) is displayed?<br />
Y N<br />
Disconnect connector J7. Check wires for Short Circuit across leads. (Orange3 & Violet10)<br />
Is there a short Circuit?<br />
Y N<br />
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Disconnect plug 5P2 from PCB5 Check wires for Short Circuit across leads. (Orange2 & Violet9) Is there a Short<br />
Circuit?<br />
Y N<br />
Replace PCB5<br />
Replace wire harness<br />
Replace wire harness<br />
Replace motor STR-M8<br />
STR 028 Motor8 Open Circuit<br />
Procedure<br />
Disconnect the motor plug M8. Enter service mode and cycle the Motor M7. Measure between the Orange and Violet wire. The<br />
voltage is approximately 22VDC?<br />
Y N<br />
Disconnect connector J6 and cycle Motor M7. Measure between the Orange and Violet wire. (Orange3&Violet10). The<br />
voltage is approximately 22VDC?<br />
Y N<br />
Disconnect plug 1P2 from PCB1 and cycle Motor M7. Measure between points 2 and 9.<br />
The voltage is approximately 22VDC?<br />
Y N<br />
Replace PCB1<br />
Replace wire harness<br />
Replace wire harness<br />
Replace Motor M7
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 029 Magnet1 Open Circuit<br />
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Procedure<br />
Disconnect the Magnet1. Enter service mode and activate the Magnet. Measure between the Orange and Violet wire. The voltage is<br />
approximately 24VDC?<br />
Y N<br />
Disconnect connector J3 and activate Magnet1. Measure between the Orange and Violet wire. (Orange2&Violet4). The<br />
voltage is approximately 24VDC?<br />
Y N<br />
Replace Magnet1<br />
Disconnect plug J1 and activate Magnet1. Measure between the orange and the violet wire (Orange6 & Violet12)<br />
The voltage is approximately 24VDC?<br />
Y N<br />
Disconnect connector 3p4 and 1p2, activate Magnet1. Measure between point 2 on 3p4 and point 12 on<br />
1p2. The voltage is approximately 24VDC?<br />
Y N<br />
Replace PCB1, reconnect all wires.<br />
Run the diagnostics. Fault code STR 029 (Open Circuit) is displayed?<br />
Y N<br />
No action<br />
Replace PCB3<br />
Replace wire harness<br />
Replace wire harness<br />
Replace wire harness
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 030 Magnet1 Short Circuit<br />
Procedure<br />
Disconnect the Magnet plug J3. Run the diagnostics. Fault code STR 029(Open Circuit) is displayed?<br />
Y N<br />
Disconnect connector J1. Check wires for Short Circuit across leads. (Orange6 & Violet 12)<br />
Is there a short Circuit?<br />
Y N<br />
Disconnect plug 1P2 from PCB1 Check wire for Short Circuit across leads. (Violet12)<br />
Is there a Short Circuit?<br />
Y N<br />
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Disconnect connector 3P11 from PCB3. Check wire for Short Circuit across leads. (Orange1) Is there a<br />
short Circuit?<br />
Y N<br />
Replace PCB1<br />
Run the diagnostics again. Fault code STR 029(Open Circuit) is displayed?<br />
Y N<br />
Replace PCB3<br />
Reconnect all wires.<br />
Replace wire harness<br />
Replace wire harness<br />
Replace wire harness<br />
Replace motor STR-M6<br />
STR 032 Stacker Motor1 Open Circuit<br />
Procedure<br />
Check if the Belt stacker is connected Belt stacker is connected?<br />
Y N<br />
Connect Belt Stacker.<br />
Disconnect Belt Stacker connector J12 and activate Belt Stacker Motor1. Measure between points 3 and 4.<br />
The voltage is approximately 22VDC?<br />
Y N<br />
Disconnect connector J1. Measure between points 5 and 11. The voltage is approximately 22VDC?<br />
Y N<br />
Disconnect plug 1P2 from PCB1 Measure between point 3 and 10. The voltage is approximately 22VDC?<br />
Y N<br />
Replace PCB1<br />
Replace wire harness<br />
Replace wire harness<br />
Belt Stacker Motor1
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 033 Stacker Motor1 Short Circuit<br />
Procedure<br />
Disconnect the Stacker Motor connector J12. Run the diagnostics. Fault code STR 032(Open Circuit) is displayed?<br />
Y N<br />
Disconnect connector J1. Check wires for Short Circuit across leads. (Orange5 & Violet 11)<br />
Is there a short Circuit?<br />
Y N<br />
Disconnect plug 1P2 from PCB1 Check wires for Short Circuit across leads.<br />
(Orange3 & Violet10) Is there a Short Circuit?<br />
Y N<br />
Replace PCB1<br />
Replace wire harness<br />
Replace wire harness<br />
Replace Stacker Motor<br />
STR 041 Jogger1 Not Home<br />
Procedure<br />
Check Jogger1 switch (S11). Is the switch activated?<br />
Y N<br />
Check if Side Jogger isn’t damaged or loosened. Side Jogger is ok?<br />
Y N<br />
Replace Side Jogger<br />
Correct NVM values of Side Jogger<br />
Check if S11 is activated using the service menu. S11 is activated?<br />
Y N<br />
Retest procedure<br />
Replace wire harness<br />
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5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 042 Jogger2 Not Home<br />
Procedure<br />
Check Jogger2 switch (S13). Is the switch activated?<br />
Y N<br />
Check if Side Jogger isn’t damaged or loosened. Side Jogger is ok?<br />
Y N<br />
Replace Side Jogger<br />
Correct NVM values of Side Jogger<br />
Check if S13 is activated using the service menu. S13 is activated?<br />
Y N<br />
Retest procedure<br />
Replace wire harness<br />
STR 043 Motor6 home to high<br />
Procedure<br />
Check Switch (S1). Is the switch activated?<br />
Y N<br />
Check if S1 isn’t damaged or loosened. Switch is ok?<br />
Y N<br />
Replace or adjust Switch S1 (See Chap. 6.3.4.)<br />
Correct NVM values of S1 lower than 2000?<br />
Y N<br />
Adjust S1 and calibrate (See Chap. 6.3.4.)<br />
Check for obstructions and retest procedure.<br />
Check if S1 is activated using the service menu. S1 is activated?<br />
Y N<br />
Retest procedure<br />
Replace wire harness<br />
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5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 045 No response from MD6DC PCB1<br />
Procedure<br />
Check if the Yellow LED on PCB1 Blinks. Does the Yellow LED blink?<br />
Y N<br />
Attempt software download on PCB1. Software download succeeds?<br />
Y N<br />
Replace PCB1<br />
Check dipswitches on PCB1. Dipswitches are set to “0000”?<br />
Y N<br />
Set dipswitches to “0000” and restart procedure.<br />
Check dipswitches on PCB5. Dipswitches are set to “1001”?<br />
Y N<br />
Set dipswitches to “1001” and restart procedure.<br />
Check endresistors on PCB1 (1P4) and PCB6 (6P3). The endresistors appear to be undamaged?<br />
Y N<br />
Replace damaged endresistors.<br />
Check wiring between PCB1 and PCB5. Are there any loose or broken wires?<br />
Y N<br />
Check wiring between PCB5 and PCB6. Are there any loose or broken wires?<br />
Y N<br />
Replace PCB1<br />
Replace wiring harness<br />
Replace wiring harness<br />
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5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 046 No response from MD6DC PCB5<br />
Procedure<br />
Check if the Yellow LED on PCB5 Blinks. Does the Yellow LED blink?<br />
Y N<br />
Attempt software download on PCB5. Software download succeeds?<br />
Y N<br />
Replace PCB5<br />
Check dipswitches on PCB5. Dipswitches are set to “1001”?<br />
Y N<br />
Set dipswitches to “1001” and restart procedure.<br />
Check dipswitches on PCB1. Dipswitches are set to “0000”?<br />
Y N<br />
Set dipswitches to “0000” and restart procedure.<br />
Check endresistors on PCB1 (1P4) and PCB6 (6P3). The endresistors appear to be undamaged?<br />
Y N<br />
Replace damaged endresistors.<br />
Check wiring between PCB1 and PCB5. Are there any loose or broken wires?<br />
Y N<br />
Check wiring between PCB5 and PCB6. Are there any loose or broken wires?<br />
Y N<br />
Replace PCB5<br />
Replace wiring harness<br />
Replace wiring harness<br />
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5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 051 FC1 Faulty<br />
Fault code STR 051 indicates that Sensor FC1 (STR-FC1) is faulty.<br />
Procedure<br />
Enter service mode and select FC1 (STR-FC1) in sensors.<br />
Value toggles between “0” and “1” when activated/deactivated?<br />
Y N<br />
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Disconnect the connector to sensor FC1. Measure between the wires to sensor FC1 (24V and Ground) The voltage is<br />
approximately 24VDC?<br />
Y N<br />
Disconnect connector J4. Measure between the wires in Plug P4 (1 & 4) The voltage is approximately 24VDC?<br />
Y N<br />
Replace wire harness<br />
Disconnect the connector 1P13. Measure between points 8 and 9.<br />
The voltage is approximately 5VDC?<br />
Y N<br />
Replace PCB1<br />
1. Replace wire harness<br />
2. Replace PCB2<br />
Adjust or replace sensor FC1 (STR-FC1)<br />
Check for obstructions and retest procedure.<br />
STR 052 FC2 Faulty<br />
Fault code STR 052 indicates that Sensor FC2 (STR-FC2) is faulty.<br />
Procedure<br />
Enter service mode and select FC2 (STR-FC2) in sensors.<br />
Value toggles between “0” and “1” when activated/deactivated?<br />
Y N<br />
Disconnect the connector to sensor FC2. Measure between the wires to sensor FC2 (24V and Ground) The voltage is<br />
approximately 24VDC?<br />
Y N<br />
Disconnect connector J4. Measure between the wires in Plug P4 (3 & 6) The voltage is approximately 24VDC?<br />
Y N<br />
Replace wire harness<br />
Disconnect the connector 1P13. Measure between points 11 and 12.<br />
The voltage is approximately 5VDC?<br />
Y N<br />
Replace PCB1<br />
1. Replace wire harness<br />
2. Replace PCB2<br />
Adjust or replace sensor FC2 (STR-FC2)<br />
Check for obstructions and retest procedure.
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 053 FC3 Faulty<br />
Fault code STR 053 indicates that Sensor FC3 (STR-FC3) is faulty.<br />
Procedure<br />
Enter service mode and select FC3 (STR-FC3) in sensors.<br />
Value toggles between “0” and “1” when activated/deactivated?<br />
Y N<br />
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Disconnect the connector to sensor FC3. Measure between the wires to sensor FC3 (24V and Ground) The voltage is<br />
approximately 24VDC?<br />
Y N<br />
Disconnect the connector 1P13. Measure between points 24 and 25.<br />
The voltage is approximately 5VDC?<br />
Y N<br />
Replace PCB1<br />
1. Replace wire harness<br />
2. Replace PCB2<br />
Adjust or replace sensor FC3 (STR-FC3)<br />
Check for obstructions and retest procedure<br />
STR 054 FC4 or FC7 Faulty<br />
Fault code STR 054 indicates that Sensor FC4 or FC7 (STR-FC4 or FC7) is faulty.<br />
Procedure<br />
Enter service mode and select FC4 or FC7 (STR-FC4 or FC7) in sensors.<br />
Value toggles between “0” and “1” when activated/deactivated?<br />
Y N<br />
Disconnect the connector to sensor FC4 or FC7. Measure between the wires to sensor FC4 or FC7 (24V and Ground) The<br />
voltage is approximately 24VDC?<br />
Y N<br />
Disconnect the connector 1P13. Measure between points 8 and 9.<br />
The voltage is approximately 5VDC?<br />
Y N<br />
Replace PCB1<br />
1. Replace wire harness<br />
2. Replace PCB2<br />
Adjust or replace sensor FC4 or FC7 (STR-FC4 or FC7)<br />
Check for obstructions and retest procedure
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 055 ENC5 Faulty<br />
• Go to STR 013 – Motor5 Pulse Timeout<br />
STR 056 ENC6 Faulty<br />
• Go to STR 017 – Motor6 Pulse Timeout<br />
STR 057 ENC7 Faulty<br />
• Go to STR 021 – Motor7 Pulse Timeout<br />
STR 058 ENC8 Faulty<br />
• Go to STR 025 – Motor8 Pulse Timeout<br />
STR 059 FC6 Faulty<br />
Fault code STR 059 indicates that Sensor FC6 (STR-FC6) is faulty.<br />
Procedure<br />
Enter service mode and select FC6 (STR-FC6) in sensors.<br />
Value toggles between “0” and “1” when activated/deactivated?<br />
Y N<br />
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Disconnect the connector to sensor FC6. Measure between the wires to sensor FC6 (5V and Ground) The voltage is<br />
approximately 5VDC?<br />
Y N<br />
Check wires for damage. Are the wires damaged?<br />
Y N<br />
Replace PCB6<br />
Replace wire harness<br />
Adjust or replace sensor FC6 (STR-FC6)<br />
Check for obstructions, check adjustment FC6 and retest procedure.
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 061 S1 Faulty<br />
Procedure<br />
Enter Service mode and select S1 in switches.<br />
Value toggles between “0” and “1” when switch S1 is activated/deactivated?<br />
Y N<br />
STR 062 S2 Faulty<br />
Procedure<br />
STR 063 Interlock Circuit Faulty<br />
Procedure<br />
Check K2 for damage. There is damage to K2?<br />
Y N<br />
Replace K2<br />
1. Replace S1<br />
2. Disconnect the plugs from switch STR-S1. Check wires for Continuity/Short circuit across leads.<br />
Is there a short circuit/no continuity?<br />
Y N<br />
Replace PCB5<br />
Check mechanics<br />
Check if K2 isn’t loose. K2 is loose?<br />
Y N<br />
Tighten K2<br />
Replace wire harness<br />
Enter Service mode and select S2 in switches.<br />
Value toggles between “0” and “1” when switch S2 is activated/deactivated?<br />
Y N<br />
1. Replace S2<br />
2. Disconnect the plugs from switch STR-S2. Check wires for Continuity/Short circuit across leads.<br />
Is there a short circuit/no continuity?<br />
Y N<br />
Replace PCB5<br />
Check Mechanics<br />
Replace wire harness<br />
Check the wiring for K2. Connectors 3P12 and 3P14 are plugged in?<br />
Y N<br />
Connect 3P12 and 3P14<br />
Replace wire harness<br />
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5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 064 S3 S4 S7 S8 Faulty<br />
Procedure<br />
Check S3/S4/S7/S8 for damage. There is damage to S3/S4/S7/S8?<br />
Y N<br />
Check if S3/S4/S7/S8 isn’t loose. S3/S4/S7/S8 is loose?<br />
Y N<br />
Check is S3/S4/S7/S8 isn’t obstructed. S3/S4/S7/S8 is obstructed?<br />
Y N<br />
Check wiring for S3/S4/S7/S8. Is there damage on the wiring or a short circuit?<br />
Y N<br />
Check K2. Is K2 damaged?<br />
Y N<br />
Replace K2<br />
Replace wire harness<br />
Remove obstruction<br />
Tighten S3/S4/S7/S8<br />
Replace S3/S4/S7/S8<br />
STR 065 S9 Faulty<br />
Replace S3/S4/S7/S8.<br />
Procedure<br />
Enter Service mode and select S9 in switches.<br />
Value toggles between “0” and “1” when switch S9 is activated/deactivated?<br />
Y N<br />
1. Replace S9<br />
2. Disconnect the plugs from switch STR-S9. Check wires for Continuity/Short circuit across leads.<br />
Is there a short circuit/no continuity?<br />
Y N<br />
Replace PCB6<br />
Check mechanics<br />
Replace wire harness<br />
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5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 066 S10 Faulty<br />
Procedure<br />
Enter Service mode and select S10 in switches.<br />
Value toggles between “0” and “1” when switch S10 is activated/deactivated?<br />
Y N<br />
STR 067 S11 Faulty<br />
Procedure<br />
STR 068 S12 Faulty<br />
Procedure<br />
1. Replace S10<br />
2. Disconnect the plugs from switch STR-S10. Check wires for Continuity/Short circuit across leads.<br />
Is there a short circuit/no continuity?<br />
Y N<br />
Replace PCB1<br />
Check mechanics<br />
Replace wire harness<br />
Enter Service mode and select S11 in switches.<br />
Value toggles between “0” and “1” when switch S11 is activated/deactivated?<br />
Y N<br />
1. Replace S11<br />
2. Disconnect the plugs from switch STR-S11. Check wires for Continuity/Short circuit across leads.<br />
Is there a short circuit/no continuity?<br />
Y N<br />
Replace PCB1<br />
Check mechanics<br />
Replace wire harness<br />
Enter Service mode and select S12 in switches.<br />
Value toggles between “0” and “1” when switch S12 is activated/deactivated?<br />
Y N<br />
1. Replace S12<br />
2. Disconnect the plugs from switch STR-S12. Check wires for Continuity/Short circuit across leads.<br />
Is there a short circuit/no continuity?<br />
Y N<br />
Replace PCB5<br />
Check mechanics<br />
Replace wire harness<br />
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5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 069 S13 Faulty<br />
Procedure<br />
Enter Service mode and select S13 in switches.<br />
Value toggles between “0” and “1” when switch S13 is activated/deactivated?<br />
Y N<br />
STR 070 S19 Faulty<br />
Procedure<br />
1. Replace S13<br />
2. Disconnect the plugs from switch STR-S13. Check wires for Continuity/Short circuit across leads.<br />
Is there a short circuit/no continuity?<br />
Y N<br />
Replace PCB5<br />
Check mechanics<br />
Replace wire harness<br />
Enter Service mode and select S19 in switches.<br />
Value toggles between “0” and “1” when switch S19 is activated/deactivated?<br />
Y N<br />
1. Replace S19<br />
2. Disconnect the plugs from switch STR-S19. Check wires for Continuity/Short circuit across leads.<br />
Is there a short circuit/no continuity?<br />
Y N<br />
Replace PCB1<br />
Check mechanics<br />
Replace wire harness<br />
STR 071 S18 Faulty<br />
Not available.<br />
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5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 080 36V input Low<br />
Procedure<br />
Power on machine. Measure incoming voltage on Rectifier (Black and Black).<br />
The voltage is approximately 26V?<br />
Y N<br />
Check if Fuse F15 is blown. Fuse F15 is blown?<br />
Y N<br />
Replace transformer<br />
Replace Fuse F15<br />
Measure outgoing voltage on rectifier (Red and Black). The voltage is approximately 26V?<br />
Y N<br />
Replace rectifier<br />
Measure outgoing voltage on the Transformer between the Orange and Violet wire. The voltage is approximately 10V?<br />
Y N<br />
Check if Fuse F14 is blown. Fuse F14 is blown?<br />
Y N<br />
Replace transformer<br />
Replace Fuse F14<br />
Power off the machine. Measure the Orange wire. Is there continuity?<br />
Y N<br />
Replace wire harness<br />
Measure the Violet wire. Is there continuity?<br />
Y N<br />
Replace wire harness<br />
Measure the Black wire. Is there continuity?<br />
Y N<br />
Replace wire harness<br />
Measure the Red wire. Is there continuity?<br />
Y N<br />
Replace PCB3<br />
Replace wire harness<br />
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5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 081 36V input High<br />
• Go to STR 080 – 36V input Low<br />
STR 082 36V output Low<br />
• Go to STR 080 – 36V input Low<br />
STR 083 36V output High<br />
• Go to STR 080 – 36V input Low<br />
STR 084 24V Low<br />
Disconnect connector 3P6. Measure between the wires (Red1 & Black3) The voltage is approximately 24V?<br />
Y N<br />
Replace PCB3<br />
Check the wires for damage or short circuit across leads. Is there damage or a short circuit?<br />
Y N<br />
Replace transformer<br />
Replace wire harness<br />
STR 085 24V High<br />
• Go to STR 088 – 24V Low<br />
STR 086 36V M6DC PCB1 Low<br />
Disconnect connector 1P11. Measure between the wires (Red1&Black2) The voltage is approximately 36VDC?<br />
Y N<br />
Replace PCB1<br />
Check 1P11 wire for damage or Short Circuit across leads. (Red1&Black2) Is there damage or a short Circuit?<br />
Y N<br />
Disconnect connector 3P5. Measure between pin 1 and pin2. The voltage is approximately 36VDC?<br />
Y N<br />
Replace PCB3<br />
1. Replace wire harness<br />
2. Replace K1<br />
Replace wire harness<br />
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5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 087 36V M6DC PCB1 High<br />
• Go to STR 086 – 36V M6DC PCB1 Low<br />
STR 088 36V M6DC PCB5 Low<br />
Disconnect connector 5P11. Measure between the wires (Red1&Black2) The voltage is approximately 36VDC?<br />
Y N<br />
Replace PCB5<br />
Check 5P11 wire for damage or Short Circuit across leads. (Red1&Black2) Is there damage or a short Circuit?<br />
Y N<br />
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Disconnect plug J1. Measure between the wires (Red1&Black7) The voltage is approximately 36VDC?<br />
Y N<br />
Check J11 wire for damage or Short Circuit across leads. (Red1&Black7) Is there damage or a short<br />
Circuit?<br />
Y N<br />
Disconnect connector 3P1. Measure between pin 1 and pin2. The voltage is approximately<br />
36VDC?<br />
Y N<br />
Replace PCB3<br />
1. Replace wire harness<br />
2. Replace K1<br />
Replace wire harness<br />
Replace wire harness<br />
Replace wire harness<br />
STR 089 36V M6DC PCB5 High<br />
• Go to STR 088 – 36V M6DC PCB5 Low
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 101 JAM FC3 NOT COVERED<br />
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Fault code STR 101, indicates that during a run, the Infeed paper path sensor (FC3), was not covered within timeout after the sheet exit<br />
signal from the previous finisher was detected.<br />
Procedure<br />
Clear paper area, by opening the cover and remove the booklet. Block and unblock Infeed paper path sensor (FC3) with a sheet of<br />
paper. The Infeed paper path sensor lights up when the sensor is blocked and doesn’t light up when the sensor is not<br />
blocked?<br />
Y N<br />
Go to STR 053 FC3 Faulty.<br />
Make sure that nothing interferes with the paper path and close cover.<br />
STR 102 JAM FC3 NOT UNCOVERED<br />
Fault code STR 102, indicates that during a run, the Infeed paper path sensor (FC3), was covered exceeding timeout.<br />
Procedure<br />
Clear paper area, by opening the cover and remove the booklet. The Infeed paper path sensor (FC3) is deactivated?<br />
Y N<br />
Go to STR 053 FC3 Faulty.<br />
Make sure that nothing interferes with the paper path and close cover.<br />
STR 103 JAM FC2 NOT COVERED<br />
Fault code STR 103, indicates that during a run, the Paper path sensor (FC2), was not covered within timeout.<br />
Procedure<br />
Clear paper area, by opening the cover and remove the booklet. Block and unblock Paper path sensor (FC2) with a sheet of paper.<br />
The Paper path sensor lights up when the sensor is blocked and doesn’t light up when the sensor is not blocked?<br />
Y N<br />
Go to STR 052 FC2 Faulty.<br />
Make sure that nothing interferes with the paper path and close cover.<br />
STR 104 JAM FC2 NOT UNCOVERED<br />
Fault code STR 104, indicates that during a run, Paper path sensor (FC2), was covered exceeding timeout.<br />
Procedure<br />
Clear paper area, by opening the cover and remove the booklet. The Paper path sensor (FC2) is deactivated?<br />
Y N<br />
Go to STR 052 FC2 Faulty.<br />
Make sure that nothing interferes with the paper path and close cover.
5. Troubleshooting (<strong>continued</strong>)<br />
5.3 Fault Code Solutions (<strong>continued</strong>)<br />
STR 105 JAM FC1 NOT COVERED<br />
Fault code STR 105, indicates that during a run, the Outfeed paper path sensor (FC1), was not covered within timeout.<br />
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Procedure<br />
Clear paper area, by opening the cover and remove the booklet. Block and unblock Outfeed paper path sensor (FC1) with a sheet of<br />
paper. The Outfeed paper path sensor lights up when the sensor is blocked and doesn’t light up when the sensor is not<br />
blocked?<br />
Y N<br />
Go to STR 051 FC1 Faulty.<br />
Make sure that nothing interferes with the paper path and close cover.<br />
STR 106 JAM FC1 NOT UNCOVERED<br />
Fault code STR 106, indicates that during a run, the Outfeed paper path sensor (FC1), was covered exceeding timeout.<br />
Procedure<br />
Clear paper area, by opening the cover and remove the booklet. The Outfeed paper path sensor (FC1) is deactivated?<br />
Y N<br />
Go STR 051 FC1 Faulty.<br />
Make sure that nothing interferes with the paper path and close cover.<br />
STR 107 JAM FC4 or FC7 WASTE BIN FULL<br />
Fault code STR 107, indicates that during a run, the Waste bin sensor (FC4 or FC7), was covered for 5 sec and 10 booklets.<br />
Procedure<br />
Clear paper area, by opening the waste bin and remove the strips. Block and unblock Waste bin sensor (FC4 or FC7) with a sheet of<br />
paper. The Waste bin sensor lights up when the sensor is blocked and doesn’t light up when the sensor is not blocked?<br />
Y N<br />
Go to STR 054 FC4 or FC7 Faulty.<br />
1. Make sure that nothing interferes with the waste bin and close the waste bin.
6. Default / basic adjustments<br />
ATTENTION<br />
In cases there was use of Loctite by some parts this is indicated<br />
with a black dot near that place [Fig. 6.1a].<br />
Make sure that adjusted or replaced parts are also provided<br />
with Loctite.<br />
6.1 Replacing Knives<br />
WARNING!!!<br />
Always stay clear from upper knife. The knife edge may cause serious<br />
injuries. Place the safety block [Fig. 6.1b] between lower knife and<br />
upper knife beam.<br />
Keep the safety block in that position as much time as possible<br />
throughout this procedure.<br />
6.1.1 Preparation<br />
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Fig. 6.1a<br />
Fig. 6.1b<br />
No. Action Remarks<br />
1 Set the STR to A5 paper size using the User Interface (display)<br />
2 Turn OFF Side Trim in the UI.<br />
3 Turn OFF the power switch and disconnect the power to the STR.<br />
4 Undock the STR from other machines.<br />
5 Remove the Front or Rear* Cover. *Depending on knife.<br />
6 Open the Top Cover.
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.1 Replacing Knives (<strong>continued</strong>)<br />
6.1.2 Removal Upper Knife<br />
Fig. 6.2<br />
E<br />
Fig. 6.5<br />
A<br />
Upper knife<br />
B<br />
Lower knife<br />
Trim Waste Fan<br />
Removal<br />
No. Action Remarks<br />
1 Remove Allen screws [A] and washers at both sides of the Knife<br />
Protection Plate.<br />
(See Fig. 6.2)<br />
2 Remove Knife Safety Plate [B] or Trim Waste Fan. (See Fig. 6.2)<br />
3 Place the Knife Protection Plate [C] or [D]* using 2 screws M6x10. *Depending on knife.<br />
(See Fig. 6.3 & 6.4)<br />
4 Remove Screws [E] (6X) with cup spring washers. (See Fig. 6.5)<br />
5 Remove Upper Knife. (See Fig. 6.5)<br />
Placement<br />
No. Action Remarks<br />
1 !!! For placement follow the Placement instructions Upper Knife. (See Chap. 6.1.5)<br />
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Contents<br />
Fig. 6.3<br />
Fig. 6.4
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.1 Replacing Knives (<strong>continued</strong>)<br />
6.1.3 Removal Lower Knife<br />
Fig. 6.6<br />
Removal<br />
No. Action Remarks<br />
1 Remove Screws [F] with normal Washers (6x) (See Fig. 6.6)<br />
2 Remove Lower Knife. (See Fig. 6.5)<br />
3 Loosen Nuts [L] (3x) (See Fig. 6.5)<br />
4 Turn Screws [M] (3x) Counter Clockwise (CCW) until they passes<br />
edge [N]<br />
(See Fig. 6.5)<br />
F<br />
5 1 3 4 2 6<br />
L<br />
M<br />
CCW CCW CCW<br />
Placement<br />
No. Action Remarks<br />
1 !!! For placement follow the Placement Lower Knife Instructions. (See Chap. 6.1.4)<br />
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6. Default / basic adjustments (<strong>continued</strong>)<br />
6.1 Replacing Knives (<strong>continued</strong>)<br />
6.1.4 Placement Lower Knife<br />
1<br />
F<br />
M<br />
Placement<br />
No. Action Remarks<br />
1<br />
Grease the bottom side surface of the Lower Knife [1] (not the<br />
paper side!) a little bit and the Knife position on the Beam [2].<br />
(See 1 & 2)<br />
2 Place the Lower Knife on the Beam against the Screws [M] (3x) (See Fig. 6.10)<br />
3 Place the Screws [F] with normal Washers (6x) back.<br />
4 Place a Safety Block between the Lower Knife and Upper Beam (See 3)<br />
5<br />
Turn the Screws [F] a little bit in the Lower Knife so the top of the<br />
screws do not stick out and the Lower Knife is hard to move.<br />
6 Remove the Safety Block<br />
7 Continue Adjustment Lower Knife. (See Chap. 6.1.7)<br />
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6. Default / basic adjustments (<strong>continued</strong>)<br />
6.1 Replacing Knives (<strong>continued</strong>)<br />
6.1.5 Placement Upper Knife<br />
Fig. 6.7<br />
E<br />
J<br />
H<br />
K<br />
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Upper knife<br />
Lower knife<br />
Contents<br />
Placement<br />
No. Action Remarks<br />
1<br />
Place the Knife Protection Plate [C] or [D]* using 2 screws M6x10<br />
on the new Knife.<br />
*Depending on knife<br />
(See Fig. 6.3 & 6.4)<br />
2 Fit the Upper Knife on the guide bar [H]. (See Fig. 6.7)<br />
3<br />
Place, (don’t tighten) Screws [E] (6X) with Washers and 6 Cup<br />
Spring Washers in the Upper Knife / block<br />
Turn Screws [E] so there is no tension and no play between the<br />
Make sure each screw has 7<br />
Cup Spring Washers placed<br />
according to Fig. 6.7<br />
4 Cup Spring Washers. (The Washers can still be turned by the<br />
fingers)<br />
(See Fig. 6.7)<br />
5 Turn Screws [E] one revolution (360º) clockwise each. (See Fig. 6.7)<br />
6 Continue Adjustment Upper Knife. (See Chap. 6.1.6)
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.1 Replacing Knives (<strong>continued</strong>)<br />
6.1.6 Adjustment Upper Knife<br />
Fig. 6.8<br />
Fig. 6.9<br />
O<br />
R<br />
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Adjusting<br />
No. Action Remarks<br />
1<br />
Check if the space [J] between the Upper Knife and the Marked<br />
Screws [R] is 0.50mm<br />
Use a feeler gauge 0.50mm.<br />
(See Fig. 6.7)<br />
2 Adjust the space if necessary with Screws [O]<br />
Never adjust Screws [R] (See<br />
Fig. 6.8)<br />
3 Turn Screws [E] two times (90º) clockwise each. (See Fig. 6.7)<br />
4<br />
Place the Knife Safety Plate [B] or Trim Waste Fan back by using<br />
Allen Screws [A] with washers.<br />
(See Fig. 6.2)<br />
5<br />
Turn the Upper Knife down in the lowest position using by turning<br />
Crank [P] with a 13mm Wrench.<br />
(See Fig. 6.9)<br />
P
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.1 Replacing Knives (<strong>continued</strong>)<br />
6.1.7 Adjustment Lower Knife<br />
5 1 3 4 2 6<br />
L<br />
M<br />
CCW CCW CCW<br />
F<br />
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Fig. 6.10<br />
Adjusting<br />
No. Action Remarks<br />
1 Gently push the Lower Knife against the Upper Knife [ 1 ].<br />
Feel that the Knives touch on<br />
both sides (See 1)<br />
2<br />
Gently raise the Upper Knife to top position using by turning<br />
Crank [P] with a 13mm Wrench.<br />
(See Fig. 6.9)<br />
3 Tighten Screws [G] 1-2 (See Fig. 6.10)<br />
4<br />
Turn Screws [M] (3x) until they touch the Lower Knife.<br />
!!! Do not force the Screws, they only need to touch the Knife<br />
(See Fig. 6.10)<br />
5<br />
Trim a booklet 4 sheets.<br />
Very slowly lower the Upper Knife by turning Crank [P].<br />
!!! Check that the Upper Knife does not touch the top of the<br />
Lower Knife.<br />
When it does hits the top of the<br />
Lower Knife, pull back the<br />
Lower Knife and repeat<br />
procedure “Adjustment Upper<br />
Knife” No. 1.<br />
G<br />
N<br />
1
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.1 Replacing Knives (<strong>continued</strong>)<br />
6.1.7 Adjustment Lower Knife (<strong>continued</strong>)<br />
Left<br />
M<br />
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Contents<br />
Adjusting<br />
No. Action Remarks<br />
17<br />
Check the booklet 4 sheets trim quality.<br />
!!! Make sure there is no tearing, folding or sticking.<br />
Loosen Screws [G] (See Fig. 6.10).<br />
Determine witch Screws [M] needs to be adjusted (to adjust the<br />
For adjusting trim quality<br />
continue next step.<br />
18 Lower Knife)<br />
Adjust Screws [M] by turning them only (10º) each time.<br />
After that, tighten Screws [G] again and trim a booklet 4 sheets.<br />
It becomes very precisely!!!<br />
19<br />
Check the booklet 4 sheets trim quality.<br />
!!! Make sure there is no tearing, folding or sticking.<br />
If necessary repeat previous<br />
step.<br />
20 Tighten Screws [F] 3-6.<br />
Trim a booklet of 25 sheets.<br />
Tighten according to Sequence<br />
1-6 (See Fig. 6.10)<br />
21 Use the Service Mode (See Chap. 5.1.3) to cycle Motor2 or<br />
Motor4.<br />
22<br />
Check the booklet 25 sheets trim quality.<br />
!!! Make sure there is no tearing, folding or sticking.<br />
23 Tighten Screws [M] (3x) by fasten Nuts [L] (3x). (See Fig. 6.10)<br />
M<br />
Right<br />
M
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.1 Replacing Knives (<strong>continued</strong>)<br />
6.1.8 Spine Support Knives<br />
For replacing the Spine Support Knives see Installation Manual SSK-kit (DBCI-0512-0042-0000).<br />
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6. Default / basic adjustments (<strong>continued</strong>)<br />
6.1 Replacing Knives (<strong>continued</strong>)<br />
6.1.9 Testing / Finishing Adjustments<br />
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Testing<br />
No. Action Remarks<br />
1<br />
Make 4 different booklets required for the adjustment. The booklets<br />
should have 2, 15, 20 & 25 sheets A3 (11”x17”) 80gsm (20# bond)<br />
Check if the lowest sheet of<br />
2 Cut the 2 sheet booklet by turning Crank [P]. (See Fig. 6.9)<br />
the booklet is cut clean<br />
throughout the length.<br />
Check if the lowest sheet of<br />
3 Cut the 15 sheet booklet (See Fig. 6.9)<br />
the booklet is cut clean<br />
throughout the length.<br />
Check if the lowest sheet of<br />
4 Cut the 20 sheet booklet (See Fig. 6.9)<br />
the booklet is cut clean<br />
throughout the length.<br />
Check if the lowest sheet of<br />
5 Cut the 25 sheet booklet (See Fig. 6.9)<br />
the booklet is cut clean<br />
throughout the length.<br />
If the set is not correctly cut on one of the ends, loosen the five (See Fig. 6.6)<br />
Screws (F) & (G). (NOTE! Keep tightened the screw on the<br />
6 good end and loosen the one on the bad end)<br />
Turn Screw (M) on the bad end 1/36 revolution or 10°<br />
clockwise.<br />
(See Fig. 6.8)<br />
7 Tighten Screws [F] 3-6 and Screws [G] 1-2.<br />
Tighten according to<br />
Sequence 1-6 (See Fig. 6.6)<br />
8 Tighten the Nuts [L] (3X) without turning the Screws [M] (3X) (See Fig. 6.8)<br />
9 Reverse “Preparation” See Chapter 6.1.1<br />
When the knives become dull it is possible to resharpen them. The upper knife can be resharpened<br />
until it is 70 mm (2”3/4) wide at the shorter end. Resharpen at a 25° angle (See Fig. 6.11).<br />
The lower knife can be resharpened until it is 38 mm (1”½) wide. Resharpen at a 1° angle (See Fig.<br />
6.11).<br />
Fig. 6.11
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.2 Adjusting booklet quality<br />
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Before making adjustments to the STR, make sure that the fault/error is not present in previous<br />
machines. Use their Service Manual to perform a Paper Size Check.<br />
Make a booklet with Side Trim and check if the booklet is not Trapezium / Diamond shaped (Chapter 6.2.1 Trapezium / Diamond Shape<br />
Fig. 6.12). Are the front [A] and back [B] of the booklet the same size and is the booklet not Diamond shaped (Fig. 6.12)?<br />
Y N<br />
Adjust the booklet according to Chapter 6.2.1 Trapezium / diamond Shape.<br />
Make sure the Finished Size is conform the UI display (Chapter 6.2.2 Side Trim (Finished Size) Fig. 6.19). The Finished Size of the<br />
booklet is the same as indicated on the UI display ( [A] = [B] = UI ) (Fig. 6.19)?<br />
Y N<br />
Adjust the booklet according to Chapter 6.2.2 Side Trim (Finished Size).<br />
(Adjust the NVM value Motor6 Home Position Booklet width correction according to chapter 8.2.1 (TAG 1 & 2) or 8.3.1 (TAG 6<br />
and up)<br />
Make sure the Side Joggers are set at a correct distance. Are the Side Joggers not deforming the booklet?<br />
-The Side Joggers should not compress the booklet to hard or to less.<br />
-There should be no more than 0,5mm space between the booklet and the Side Joggers.<br />
Y N<br />
Adjust the NVM values No. 3 Motor7 and No. 5 Motor 8 Compress Correction according to Chapter 8.2.2 (TAG 1&2) or 8.3.2<br />
(TAG 6 and up)<br />
Make sure the booklet is not skewed. All corners are 90degrees?<br />
Y N<br />
Adjust the Side Joggers SQUARED against the Lower Knife according to Chapter 6.4 Replacing Side Joggers<br />
Is the booklet trim waste equal when the offset is set to 0mm?<br />
Y N<br />
Adjust the NVM value Motor7 and Motor8 Centering Correction according to Chapter 8.2.3 (TAG 1&2) or 8.3.3 (TAG 6 and up)<br />
The booklet quality is correct.
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.2 Adjusting booklet quality (<strong>continued</strong>)<br />
6.2.1 Trapezium / Diamond Shape<br />
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Make a booklet with Side Trim and check if the booklet is not Trapezium / Diamond shaped (Fig. 6.12).<br />
Is the Booklet size [ A = B ] (Fig. 6.12) the same as the Finished Size indicated on the display and is<br />
the Booklet not Diamond shaped (See corners C) ?<br />
Y N<br />
Proceed adjusting Trapezium / Diamond Shape on this and following pages.<br />
Continue adjusting Side Trim (Finished Size) (See Chapter 6.2.2 Side Trim (Finished Size) )<br />
A B A<br />
B<br />
C<br />
C<br />
Fig. 6.12
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.2 Adjusting booklet quality (<strong>continued</strong>)<br />
6.2.1 Trapezium / diamond Shape (<strong>continued</strong>)<br />
C<br />
A<br />
Adjusting<br />
No. Action Remarks<br />
1 Check that the Paper stop is right angled with the Lower Knives:<br />
Place a square (>35cm) over the Lower knives and the Transport belts<br />
with one side against the Lower knife.<br />
See A.<br />
ATTENTION!!! Be very careful with hands near the Lower knives!<br />
And pay attention not to damage the Lower knives<br />
with the square!!!<br />
See B.<br />
2 Move the square along the Lower knife against the Paper stop. See C.<br />
3 Check if there is space between the square and the Paper stop.<br />
Is there is space, adjust the screws [D].<br />
Check is the Paper Stop does not touch the sides of the brackets<br />
when the Paper Stop is pushed downwards!!!<br />
See D.<br />
4 Continue adjusting Chapter 6.2.1 Trapezium / diamond Shape<br />
(<strong>continued</strong>).<br />
See next page<br />
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B<br />
D<br />
Contents
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.2 Adjusting booklet quality (<strong>continued</strong>)<br />
6.2.1 Trapezium / diamond Shape (<strong>continued</strong>)<br />
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Make a booklet with Side Trim and check if the booklet is not Trapezium / diamond shaped (Fig. 6.13)<br />
Is the Booklet size [ A = B ] (Fig. 6.13) the same as the Finished Size indicated on the display?<br />
Y N<br />
Proceed adjusting Trapezium / diamond Shape on this and following pages.<br />
Continue adjusting the booklet quality by changing the NVM values (See Chapter Adjusting NVM Values<br />
8.2.1 (TAG1 & 2) or 8.3.1 (TAG6 and up).<br />
Y<br />
Smaller Front size Bigger Front size<br />
A B A<br />
B<br />
Y<br />
X<br />
Fig. 6.13<br />
X<br />
Adjusting<br />
No. Action Remarks<br />
1 For adjusting the Trapezium / diamond Shape the ‘F (factor)’ should be<br />
determined by filling in the formula:<br />
Subtract booklet front size (A) from booklet back size (B) and ( B – A ) / 2 = Y<br />
divide the number by 2 to get value Y.<br />
2 Divide value (Y) by booklet length (X) Y / X = F (factor)<br />
3 Move wheel 1 ‘C’ number of teeth = F x 640mm / 0,25mm* Use (C) in adjustment No.<br />
1, 2 & 3 next page.<br />
4 Move wheel 2 ‘D’ number of teeth = F x 216mm / 0,25mm* Use (D) in adjustment No.<br />
4, 5 & 6 next page.<br />
NOTE: A negative number of teeth (C) or (D) means decrease A (CCW).<br />
Only move a full teeth = 0,25mm. If (C) or (D) < 0,5 tooth round down to 0 teeth,<br />
If (C) or (D) > 0,5 tooth round up to 1 tooth !!!<br />
Y
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.2 Adjusting booklet quality (<strong>continued</strong>)<br />
6.2.1 Trapezium / diamond Shape (<strong>continued</strong>)<br />
CCW CW Wheel 1<br />
Wheel 2 CCW CW<br />
A B A B<br />
Fig. 6.15 Fig. 6.16<br />
Adjusting<br />
No. Action Remarks<br />
1 Mark a tooth of wheel 1 on the tooth belt, and remove the tooth belt off<br />
the wheel before moving wheel 1.<br />
(See Fig. 6.15)<br />
2 Move wheel 1 ‘C’ number of teeth with respect to the marked tooth belt. (See Fig. 6.14)<br />
3 Place the tooth belt back on wheel 1.<br />
4 Mark a tooth of wheel 2 on the tooth belt, and remove the tooth belt off<br />
the wheel before moving wheel 2.<br />
(See Fig. 6.16)<br />
5 Move wheel 2 ‘D’ number of teeth with respect to the marked tooth belt. (See Fig. 6.14)<br />
6 Place the tooth belt back on wheel 2.<br />
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When A needs to be decreased, turn CCW and the Knife blocks will move towards each other.<br />
When A needs to be increased, turn CW and the Knife blocks will move out of each other.<br />
CCW CW<br />
CCW<br />
CW<br />
Wheel 1<br />
Fig. 6.14<br />
1 Tooth<br />
CCW (Counter Clockwise) = decrease A<br />
CW (Clockwise) = increase A<br />
Wheel 2
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.2 Adjusting booklet quality (<strong>continued</strong>)<br />
6.2.2 Side Trim (Finished Size)<br />
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Before making adjustments to the STR, make sure that the fault/error is not present in previous<br />
machines. Use their Service Manual to perform a Paper Size Check.<br />
Fig. 6.17 Fig. 6.18<br />
Fig. 6.19 Fig. 6.20<br />
Adjusting<br />
No. Action Remarks<br />
1 Make a booklet without Side Trim.<br />
2 Measure if the size of the booklet is conform the Size displayed<br />
on the UI.<br />
(See Fig. 6.17 & 6.18)<br />
If not, adjust the BM.<br />
3 Use the ‘▲ / ▼ ’ and the ‘+ / -‘ buttons to select and adjust the<br />
Side Trim / ‘Finished Size’ (e.g. 287.0mm) and press the ‘Enter’<br />
button.<br />
4 Make a booklet with Side Trim.<br />
5 Measure if the Finished Size of the booklet after trimming is<br />
conform the Size displayed on the UI.<br />
6 If the measured Finished Size is the same as UI-Finished Size the<br />
adjustment is complete.<br />
If not, adjusting the NVM Values by continue chapter:<br />
8.2 Adjusting NVM Values<br />
(See Fig. 6.19 & 6.20)<br />
(See Fig. 6.20)
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.3 Sensors and Switches<br />
6.3.1 Replace Photo Sensors<br />
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There are two different kind of Photo sensors in the STR (pay attention to the yellow squares):<br />
� HK12PB8 [Photo Sensor Reflex 18x120mm PB (Adj.)] (OSOR-0000-0001-0000)<br />
� LK89PD8 [Photo Sensor Retro-Reflex 18x120mm PD8] (OSOR-0000-0004-0000)<br />
During operating the STR it could happen that a paper jam appears and the STR signals an error code.<br />
These are easy to solve by carry out the instructions displayed on the UI and/or using the Fault Code<br />
Descriptions (See Chap. 5.2).<br />
FC1<br />
FC2<br />
FC3<br />
FC4<br />
Always open the Top Cover of the STR before clearing the paper jam.<br />
Outfeed<br />
Paper-stop sensor<br />
Infeed sensor<br />
Trim wast bin<br />
FC7 Trim wast bin
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.3 Sensors and Switches (<strong>continued</strong>)<br />
6.3.1 Replace Photo Sensors (<strong>continued</strong>)<br />
FC3<br />
FC2<br />
Fig. 6.21 Fig. 6.22<br />
FC2<br />
Fig. 6.23 Fig. 6.24<br />
Removal<br />
No. Action Remarks<br />
1 Open the Top Cover or Remove the Base plate Cover (See Chap. 4.7)<br />
2 Disconnect the orange Photo sensor cable.<br />
3 Remove the Photo sensor [HK12PB8] inside the STR. (See Fig. 6.21 – 6.24)<br />
Installation<br />
No. Action Remarks<br />
1 For installation follow the Removal procedure in reversed order.<br />
FC1<br />
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FC3<br />
FC1<br />
Contents
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.3 Sensors and Switches (<strong>continued</strong>)<br />
6.3.1 Replace Photo Sensors (<strong>continued</strong>)<br />
Fig. 6.25 Fig. 6.26<br />
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FC7<br />
Removal<br />
No. Action Remarks<br />
1 Open the Top Cover or Remove the Base plate Cover (See Chap. 4.7)<br />
2 Disconnect the orange Photo sensor cable.<br />
3 Remove the Photo sensor FC4 or FC7 [LK89PD8] inside the Base. (See Fig. 6.25 & 6.26)<br />
Installation<br />
No. Action Remarks<br />
1 For installation follow the Removal procedure in reversed order.<br />
FC4<br />
Contents
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.3 Sensors and Switches (<strong>continued</strong>)<br />
6.3.2 Adjusting Photo Sensors<br />
The Photo sensors that are used in de STR have a small<br />
yellow adjustment screw on the back. With the aid of a very<br />
small screwdriver it is possible to adjust the photo sensors.<br />
(Fig. 6.27)<br />
All photo sensors should be mounted looking straight down<br />
on the paper path (90º on the transport belts), HK12PB8 for<br />
[FC1], [FC2] and [FC3]. Or straight against the Reflection<br />
sticker, LK89PD8 for [FC4] and [FC7].<br />
Use an unprinted paper (sheet) to adjust the Photo sensors.<br />
After that adjust the Photo sensor one stripe further than it<br />
was adjusted. Other paper colors can absorb the light which<br />
the Photo sensor can not see.<br />
Photo sensors should only see the booklet between the transport<br />
belts or the paper trim waste between the Reflection sticker and<br />
the sensor.<br />
A photo sensor that is set too sensitive may see something<br />
that is not really there. If a photo sensor is not sensitive enough<br />
it might not see the booklet.<br />
When the photo sensor light is on, there is something seen<br />
in his range. When the photo sensor light is off, the range is clear.<br />
more sensitive<br />
less sensitive<br />
Fig. 6.27<br />
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6. Default / basic adjustments (<strong>continued</strong>)<br />
6.3 Sensors and Switches (<strong>continued</strong>)<br />
6.3.2 Adjusting Photo Sensors (<strong>continued</strong>)<br />
Fig. 6.28 Fig. 6.29<br />
Fig. 6.30<br />
Adjusting FC1, FC2 and FC3<br />
No. Action Remarks<br />
1 Open the Top Cover.<br />
2<br />
3<br />
4<br />
Place an unprinted paper (sheet) in front of Infeed and turn the<br />
belts to insert the paper into the STR until it lies under one of the<br />
Photo sensor (FC1or FC2 or FC3).<br />
Use a small screw driver to adjust the sensitivity of the Photo<br />
sensor until the light on top lights up.<br />
When the Photo sensor lights up, the paper is in his range.<br />
After that adjust the Photo sensor one stripe further than it was<br />
adjusted in step No. 3.<br />
It turns off when the paper is removed.<br />
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(See Fig. 6.28 & 6.29)<br />
(See Fig. 6.30)
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.3 Sensors and Switches (<strong>continued</strong>)<br />
6.3.2 Adjusting Photo Sensors (<strong>continued</strong>)<br />
Fig. 6.31 Fig. 6.32<br />
In some STR types there can be placed 2 Photo Sensors in the Base.<br />
In that case there are also 2 Reflection stickers.<br />
Adjusting FC4 and FC7<br />
No. Action Remarks<br />
1<br />
Use a small screw driver to adjust the sensitivity of the Photo<br />
sensor to the maximum.<br />
(See Fig. 6.31)<br />
2<br />
When the Photo sensor lights beam is visible on the Reflection<br />
sticker, it will be reflected to the Photo sensor.<br />
(See Fig. 6.32)<br />
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6. Default / basic adjustments (<strong>continued</strong>)<br />
6.3 Sensors and Switches (<strong>continued</strong>)<br />
6.3.3 Replace Switches<br />
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Removal<br />
No. Action Remarks<br />
1 Remove the Front or Rear Cover or Open Top Cover. (See Chap. 4.1 or 4.2)<br />
2 Switch off the main power switch and disconnect the power cord.<br />
3 Locate the replacable Switch by using Chap. 2.2.2<br />
4 Loosen the Bolts and replace the Switch.<br />
Installation<br />
No. Action Remarks<br />
1 For installation follow the Removal procedure in reversed order.
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.3 Sensors and Switches (<strong>continued</strong>)<br />
6.3.4 Adjusting Switches<br />
A<br />
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Adjusting S1<br />
No. Action Remarks<br />
Make sure or adjust that the Paperstop Unit [A] is exactly in the !!! The distances between<br />
1 middle of the Kniveblock guidance [B] on both sides.<br />
the paper stop and plates<br />
(Is necessary, remove covers. See Chap. 4).<br />
must match exactly!<br />
Move the Kniveblocks inwards to the Paperstop Unit by turning the (See Chap. 2.2.5)<br />
2<br />
Tooth belt 1 on the Control Board (Clockwise = CW) until the<br />
distance between the LowerKnives on both side is between 198mm<br />
and 199mm.<br />
B<br />
A<br />
x<br />
=<br />
198mm ≤ x ≥ 199mm<br />
BOTH SIDES!
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.3 Sensors and Switches (<strong>continued</strong>)<br />
6.3.4 Adjusting Switches (<strong>continued</strong>)<br />
S1<br />
Adjusting S1<br />
No. Action<br />
Turn the Upper Knives in the position that the Cams are as close as<br />
Remarks<br />
3 possible to each other. There should be a space of 1mm between<br />
the Cams.<br />
Adjust the Switch (S1) from the Paperstop (Knife blocks Width inner<br />
limit switch) in the middle against the Knife block.<br />
(See S1)<br />
4<br />
!!! The Switch has two positions of switching (move in and move<br />
out). When the Switch is moving out the distance between the<br />
LowerKnives on both side must be between 198mm and<br />
199mm.<br />
5 Move the Kniveblocks 5mm outwards (Counter Clock wise =CCW).<br />
Then move the Kniveblocks inwards (CW) until the Switch is<br />
6 moving in. Move the Kniveblocks outwards until the switch is<br />
moving out and stop moving the blocks.<br />
Check if the distance between the LowerKnives on both side is (See no. 2)<br />
7 between 198mm and 199mm. Otherwise adjust Switch 1 again until<br />
it switched between 198mm and 199mm.<br />
8 Check Side Trim (Finished Size) by continuing Chap. 6.22.<br />
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1mm<br />
Move in / move out<br />
Contents
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.3 Sensors and Switches (<strong>continued</strong>)<br />
6.3.4 Adjusting Switches (<strong>continued</strong>)<br />
A<br />
C<br />
Click!!<br />
B<br />
D<br />
Adjusting S2<br />
No. Action Remarks<br />
1<br />
Adjust the distance between the roll-guide [A] and the black block<br />
[B] of the Linear Guide to 5mm by turning the wheel.<br />
(See A & B)<br />
Adjust the Roller of the lever Microswitch [C] against the side that (See C & D)<br />
2<br />
activated the Microswitch [Click!] and then tighten the screws [D].<br />
!!! Make sure that the side of the Microswitch (with roller lever)<br />
does not stick out the black block (except the roller lever)!<br />
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Contents
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.3 Sensors and Switches (<strong>continued</strong>)<br />
6.3.4 Adjusting Switches (<strong>continued</strong>)<br />
Click!!<br />
2mm C<br />
Adjusting S11 & S13<br />
No. Action Remarks<br />
Adjust the Microswitch (that when the jogger plate is retracted) the (See C)<br />
1<br />
roller lever is hit and switched.<br />
!!! The red ridge [C]of the Microswitch is activated [Click!] and<br />
approximately ± 2mm pressed!<br />
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6. Default / basic adjustments (<strong>continued</strong>)<br />
6.3 Sensors and Switches (<strong>continued</strong>)<br />
6.3.4 Adjusting Switches (<strong>continued</strong>)<br />
Click!!<br />
Adjusting S10 & S12<br />
No. Action Remarks<br />
Turn the Upper Knife in the highest position.<br />
(See A)<br />
1 !!! The highest position is indicated by the black stripe on the<br />
Cam and Bolt [A] that should be in line.<br />
2<br />
Adjust the Actuator Plate [B] so that the Microswitch just switched<br />
(Click)!<br />
Make sure the Actuator Plate and Switch are properly adjusted by<br />
(See B<br />
3<br />
turning the Upper knife down and back upwards.<br />
!!! The Actuator Plate should switch the Microswitch when the<br />
Upper Knife is in the highest position (black stripe is in line).<br />
B<br />
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A<br />
Contents
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.4 Replacing / Preparing Side Joggers<br />
D<br />
Fig. 6.33 Fig. 6.34<br />
Fig. 6.35 Fig. 6.36<br />
A<br />
Removal/Replacing<br />
No. Action Remarks<br />
1<br />
Remove the Front or Rear Cover (depending on Replacing Side<br />
Jogger).<br />
(See Chap. 4.1 or 4.2)<br />
2<br />
Loosen nuts [A] and adjust the Guiding [B] & [C] on both sides of<br />
the Side Jogger bracket on equal height.<br />
(See Fig. 6.33 & 6.34)<br />
3 Tighten nuts [A]<br />
4<br />
Grease the Guiding blocks of the Side Jogger Plate on the Upper,<br />
Side and Lower side.<br />
(See Fig. 6.35)<br />
5 Place the Side Jogger Plate in the Side Jogger bracket (See Fig. 6.36)<br />
Adjust the Side Jogger Plate in the Side Jogger bracket with no (See Fig. 6.36 & 6.33)<br />
6<br />
tolerance by adjusting the bolts [D]!!!<br />
(DO NOT adjust the Side Jogger bracket to tight because the Side<br />
Jogger Plate should move in and out easily)<br />
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D<br />
B<br />
C<br />
Contents
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.4 Replacing / Preparing Side Joggers (<strong>continued</strong>)<br />
Fig. 6.37<br />
S11 / S13<br />
2mm<br />
D<br />
A<br />
Klik!!!<br />
Fig. 6.38 Fig. 6.39<br />
B<br />
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Removal/Replacing<br />
No. Action Remarks<br />
Adjust the Switch S11 or S13 inside the Side Jogger bracket. When the lever is coupled<br />
7<br />
(The Switch should couple when the tooth of the Side Jogger Plate<br />
hits the lever of the switch.)<br />
[Klik!!!] the red ridge of the<br />
Switch is pressed for about<br />
2mm. (See Fig. 6.37)<br />
8 Disconnect Connector J7/P7 or J6/P6 [A] (See Fig. 6.38)<br />
9<br />
Disconnect Side Jogger wires P-sensor8 + P-motor8 or P-sensor7<br />
+ P-motor7 [B]<br />
(See Fig. 6.38)<br />
10 Loosen bolts M6 (2X) [C] (See Fig. 6.39)<br />
Disconnect the Side Jogger switch wires<br />
(See Fig. 6.38)<br />
11 (inside the Side Jogger bracket [D] ) : white S11-3 / S13-2<br />
black S11-1 / S13-1.<br />
12<br />
Remove the ‘old’ Side Jogger and continue Adjusting Side Joggers<br />
on the next page.<br />
C
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.5 Adjusting Side Joggers<br />
D<br />
Fig. 6.40 Fig. 6.41<br />
Fig. 6.42 Fig. 6.43<br />
Removal/Replacing<br />
No. Action Remarks<br />
1 Place (new) Side Jogger and DO NOT tighten the bolts M6 [C] yet. (See Fig. 6.41)<br />
2 Connect Connector J7/P7 or J6/P6 [A] (See Fig. 6.40)<br />
3<br />
Connect Side Jogger wires P-sensor8 + P-motor8 or P-sensor7 + (See Fig. 6.40)<br />
P-motor7 [B]<br />
A<br />
B<br />
Connect the Side Jogger switch wires<br />
(See Fig. 6.40)<br />
4 (inside the Side Jogger bracket [D] ) : white S11-3 / S13-2<br />
black S11-1 / S13-1.<br />
5<br />
After replacing, the Side Joggers need to be align squared<br />
against the Lower Knifes, therefore continue No. 6.<br />
6 Enter the Service Program mode (See Chapter 5.1)<br />
7 Use the ‘▲ / ▼’ buttons to select ‘Motors’ and press ‘Enter’. (See Fig. 6.42)<br />
Use the ‘▲ / ▼’ buttons to select the Motor (M7 or M8) that needs (See Fig. 6.43)<br />
8 to be squared against the Lower Knife, press ‘Enter’ and continue<br />
next page.<br />
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6. Default / basic adjustments (<strong>continued</strong>)<br />
6.5 Adjusting Side Joggers (<strong>continued</strong>)<br />
Fig. 6.44<br />
2 times<br />
1 time<br />
Fig. 6.45 Fig. 6.46<br />
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Removal/Replacing<br />
No. Action Remarks<br />
(See Fig. 6.45)<br />
9<br />
After selecting a Motor, press the ‘In’ button 2 TIMES to move the<br />
selected Side Jogger forward against the Lower Knife.<br />
!!!DO NOT PRESS THE ‘IN’ BUTTON MORE THAN 2 TIMES!!!<br />
The Side Jogger move toward<br />
the Lower Knife and after 2<br />
times the Side Jogger will<br />
squared itself against the<br />
Lower Knife.<br />
10 Tighten the bolts M6 (2X) [C] (See Fig. 6.46)<br />
11 After checking press the ‘OFF’ buttons to change the Status of the<br />
Motor back in the ‘normal’ situation.<br />
12 Press 3 times the ‘ ’ button and ‘Exit’ to exit the Service<br />
13<br />
Program mode and enter the Operator mode.<br />
Place Front or Rear Cover. (See Chap. 4.1 or 4.2)<br />
14<br />
After adjusting the Side Joggers continue chapter ‘ 8 NVM Values’<br />
to calibrate the Side Jogger correction NVM values.<br />
8.2.2 NVM Side Jogger<br />
correction<br />
C
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.6 Adjusting Chains and Sprockets<br />
Fig. 6.47 Fig. 6.48<br />
Fig. 6.49 Fig. 6.50<br />
Adjusting<br />
No. Action Remarks<br />
1 Remover the Motorbracket on the motor axle.<br />
1<br />
After removing the Chains place a ruler against the biggest<br />
Sprocket.<br />
(See Fig. 6.47 & 6.78)<br />
2<br />
Loosen the Adjustment screw in the smaller Sprocket and slide this<br />
over the axle until the Sprocket lies against the ruler.<br />
(See Fig. 6.49)<br />
3<br />
Fasten the smaller Sprocket by tighten the Adjustment screw with a (See Fig. 6.50)<br />
little bit Loctite 243.<br />
4 Check again if the Sprocket are in line with each other. (See Fig. 6.47)<br />
5 Repeat this step for the other side of the Knife Block.<br />
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6. Default / basic adjustments (<strong>continued</strong>)<br />
6.6 Adjusting Chains and Sprockets (<strong>continued</strong>)<br />
Chain 04B1 74links (OMKI-0000-0007-0000) Chain 04B1 82links (OMKI-0000-0001-0000)<br />
SHORT LONG<br />
Fig. 6.51 Fig. 6.52<br />
SHORT<br />
Fig. 6.53 Fig. 6.54<br />
Fig. 6.55 Fig. 6.56<br />
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Contents<br />
Adjusting<br />
No. Action<br />
Place the right chain on the sprockets<br />
Remarks<br />
1<br />
The ‘long’ chain should be placed at the side where the distance (See Fig. 6.51, 6.52, 6.53 &<br />
between axes of the sprockets is the biggest.<br />
6.54)<br />
The ‘short’ chain at the smallest distance.<br />
2 Hook the links of the chains together with a separate link. (See Fig. 6.55 & 6.56)
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.6 Adjusting Chains and Sprockets (<strong>continued</strong>)<br />
Fig. 6.57 Fig. 6.58<br />
Fig. 6.59<br />
Adjusting<br />
No. Action<br />
Secure the link with the Chain closure using a flat screwdriver.<br />
Remarks<br />
1 Pay attention that the Chain closure is mounted along the<br />
rotation direction (the ‘open-side’ should be rear-facing).<br />
(See Fig. 6.57 & 6.58)<br />
2 Make sure that the Chains are in/between the Chain tensioners. (See Fig. 6.59)<br />
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6. Default / basic adjustments (<strong>continued</strong>)<br />
6.7 Motor and Encoder positions<br />
Fig. 6.59 Fig. 6.60<br />
Motor Encoders<br />
No. ENC Description Remarks<br />
A n/a Motor 3, Knife (See Fig. 6.59)<br />
B n/a Motor 4, Knife (See Fig. 6.59)<br />
F 8 Motor 8, Side Jogger (See Fig. 6.59)<br />
G 5 Motor 6, Knife width adjust (See Fig. 6.59)<br />
C n/a Motor 1, Knife (See Fig. 6.60)<br />
D n/a Motor 2, Knife (See Fig. 6.60)<br />
E 7 Motor 7, Side Jogger (See Fig. 6.60)<br />
H 6 Motor 5, Belt Propulsion (See Fig. 6.60)<br />
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A B C D<br />
G<br />
F<br />
E<br />
H
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.8 Tapping Transformer and blown fuse conditions<br />
Fig. 6.61 Fig. 6.62<br />
Fig. 6.63 Fig. 6.64<br />
Purpose of tapping Transformer<br />
To be able to change the Transformer setting, depending on different voltages.<br />
Removal/Adjusting<br />
No. Action Remarks<br />
1 Remove Rear Cover See Chap. 4.2<br />
2 NOTE!: Make sure the power cord of the STR is disconnected<br />
from the wall outlet<br />
3 Measure the wall outlet voltage (120V or 230V)<br />
4 Check to which terminal the power cable is connected.<br />
See A<br />
(The picture shows a transformer tapped for 230V)<br />
5 Tap the Transformer to 120V or 230V settings according to the<br />
label on the Transformer by moving cable [A].<br />
NOTE!: Do not move cable [B].<br />
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(See Fig. 6.61 & 6.62)<br />
6 Remove the current label ‘Disconnects only…’ (See Fig. 6.63)<br />
7 Paste the correct label ‘Disconnects only BLTXX02 230VAC<br />
50Hz’ or ‘Disconnects only BLTXX02 120VAC 60Hz’ depending<br />
on the wall outlet voltage.<br />
Included in Box with<br />
accessories<br />
(See Fig. 6.64)<br />
Installation<br />
No. Action Remarks<br />
1<br />
For placing back Rear Cover follow the Rear Cover procedure in<br />
reversed order.<br />
See Chap. 4.2<br />
B<br />
A
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.8 Tapping Transformer and blown fuse conditions (<strong>continued</strong>)<br />
F12<br />
Fuse Rate Symptom at power on<br />
F12 4AT STR no com (no response)<br />
F14 2AT STR no com (no response)<br />
F15 16AT Cover open indication<br />
Removal<br />
No. Action Remarks<br />
1 Remove Cover Left / Right See Chap. 4.2<br />
2 Check which symptom the machine shows<br />
3 Remove the blown out Fuse (Transformer [F14/ F15] or Fuse<br />
holder [F12]).<br />
Installation<br />
No. Action Remarks<br />
1 For installation follow the Removal procedure in reversed order.<br />
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F14<br />
Contents
6. Default / basic adjustments (<strong>continued</strong>)<br />
6.9 Adjusting Thickness detection<br />
Fig. 6.65 Fig. 6.66 Fig. 6.67<br />
CCW =<br />
Trim<br />
thinner<br />
booklets<br />
Fig. 6.68<br />
Fig. 6.69 Fig. 6.70<br />
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Adjusting<br />
No. Action Remarks<br />
1 Make a booklet 25 sheets 80gms and a booklet 27 sheets 80gms.<br />
2<br />
Enter the Service Program mode, select Sensors and press 2<br />
times Next and select Sensor ‘FC6 Thickness’ and press ‘Enter’.<br />
(See Chap. 5.15 & Fig. 6.69)<br />
3 Place the booklet 25 sheets halfway the Infeed of the STR. (See Fig. 6.65 & 6.66)<br />
4<br />
Adjust screw ‘A’ of the Thickness detection from inside the STR:<br />
By booklet 25 sheets 80gms the Value should be Low .<br />
NOTE!: Do not press to hard by adjusting screw A otherwise<br />
the Thickness detection is pressed backwards!<br />
(See Fig. 6.70)<br />
(See Fig. 6.67 & 6.68)<br />
5 Place the booklet 27 sheets halfway the Infeed of the STR. (See Fig. 6.65 & 6.66)<br />
6<br />
A<br />
CW =<br />
Trim<br />
thicker<br />
booklets<br />
Adjust screw ‘A’ of the Thickness detection from inside the STR:<br />
By booklet 27 sheets 80gms the Value should be High.<br />
NOTE!: Do not press to hard by adjusting screw A otherwise<br />
the Thickness detection is pressed backwards!<br />
(See Fig. 6.70)<br />
(See Fig. 6.67 & 6.68)
7. PCB’S<br />
7.1 Software download<br />
7.1.1 PCB1 MD6DC<br />
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INFORMATION This procedure may delete all Job settings. Make a note of all the settings to make<br />
sure they can be restored after downloading.<br />
WARNING!!! Turn off the main power switch and unplug the machine before attempting any of the<br />
procedures in this section.<br />
CAUTION!!! Electrostatic Discharge can cause software crashes,<br />
data and/or communications problems or damage to<br />
electronic components (e.g. : PCBs).<br />
ESD problems can be minimized by maintaining the<br />
machine with ground connections, and proper handling<br />
of circuit boards and sensors. Use ESD Ground Strap for<br />
protection when working with PCBs.<br />
Fig. 7.1 Fig. 7.2<br />
PAY ATTENTION!!! The right software application can be found in by the list of Factory Settings 2-<br />
Side Trimmer that is present inside the Back Cover.<br />
Downloading<br />
No. Action Remarks<br />
1<br />
Before downloading software application make sure the list of<br />
Factory Settings 2-Side Trimmer is present inside the Back Cover.<br />
See Chap. 8.1<br />
2 Remove Rear Cover See Chap. 4.2<br />
3 Check if the dipswitches are in the right position. See Fig. 7.2<br />
4<br />
Run the right software application for the type of machine and<br />
follow the instructions in the program.<br />
5<br />
After downloading perform a NVM reset and insert the correct NVM<br />
values according to the List in the Back Cover.<br />
See Chap. 8.1<br />
7 PCB’S (<strong>continued</strong>)<br />
1 2 3 4<br />
Contents
7.1 Software Download (<strong>continued</strong>)<br />
7.1.2 PCB5 MD6DC<br />
INFORMATION This procedure may delete all Job settings. Make a note of all the settings to make<br />
sure they can be restored after downloading.<br />
WARNING!!! Turn off the main power switch and unplug the machine before attempting any of the<br />
procedures in this section.<br />
CAUTION!!! Electrostatic Discharge can cause software crashes,<br />
data and/or communications problems or damage to<br />
electronic components (e.g. : PCBs).<br />
ESD problems can be minimized by maintaining the<br />
machine with ground connections, and proper handling<br />
of circuit boards and sensors. Use ESD Ground Strap for<br />
protection when working with PCBs.<br />
Fig. 7.3 Fig. 7.4<br />
PAY ATTENTION!!! Choose the right software application by the TAG of the machine.<br />
Please contact Service department for more information about the software.<br />
Downloading<br />
No. Action Remarks<br />
1<br />
Before downloading software application make sure the list of<br />
Factory Settings 2-Side Trimmer is present inside the Back Cover.<br />
See Chap. 8.1<br />
2 Remove Front Cover See Chap. 4.1<br />
3 Check if the dipswitches are in the right position. See Fig. 7.4<br />
4<br />
Run the right software application for the type of machine and<br />
follow the instructions in the program.<br />
5<br />
After downloading perform an NVM reset and insert the correct<br />
NVM values according to the List in the Back Cover.<br />
See Chap. 8.1<br />
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1 2 3 4
7. PCB’S (<strong>continued</strong>)<br />
7.1 Software Download (<strong>continued</strong>)<br />
7.1.3 PCB6 CPU<br />
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INFORMATION This procedure may delete all Job settings. Make a note of all the settings to make<br />
sure they can be restored after downloading.<br />
WARNING!!! Turn off the main power switch and unplug the machine before attempting any of the<br />
procedures in this section.<br />
CAUTION!!! Electrostatic Discharge can cause software crashes,<br />
data and/or communications problems or damage to<br />
electronic components (e.g. : PCBs).<br />
ESD problems can be minimized by maintaining the<br />
machine with ground connections, and proper handling<br />
of circuit boards and sensors. Use ESD Ground Strap for<br />
protection when working with PCBs.<br />
Fig. 7.5 Fig. 7.6<br />
PAY ATTENTION!!! Choose the right software application by the TAG of the machine.<br />
Please contact Service department for more information about the software.<br />
Downloading<br />
No. Action Remarks<br />
1<br />
Before downloading software application make sure the list of<br />
Factory Settings 2-Side Trimmer is present inside the Back Cover.<br />
See Chap. 8.1<br />
2 Remove Front Cover See Chap. 4.1<br />
3 Find out the type of Tag of the machine See Chap. 2.1.1<br />
4<br />
Run the right software application for the type of machine and<br />
follow the instructions in the program.<br />
5<br />
After downloading perform an NVM reset and insert the correct<br />
NVM values according to the List in the Back Cover.<br />
See Chap. 8.1
7. PCB’S (<strong>continued</strong>)<br />
7.1 Software Download (<strong>continued</strong>)<br />
7.1.4 PCB8<br />
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INFORMATION This procedure may delete all Job settings. Make a note of all the settings to make<br />
sure they can be restored after downloading.<br />
WARNING!!! Turn off the main power switch and unplug the machine before attempting any of the<br />
procedures in this section.<br />
CAUTION!!! Electrostatic Discharge can cause software crashes,<br />
data and/or communications problems or damage to<br />
electronic components (e.g. : PCBs).<br />
ESD problems can be minimized by maintaining the<br />
machine with ground connections, and proper handling<br />
of circuit boards and sensors. Use ESD Ground Strap for<br />
protection when working with PCBs.<br />
Fig. 7.5 Fig. 7.6<br />
PAY ATTENTION!!! Choose the right software application by the TAG of the machine.<br />
Please contact Service department for more information about the software.<br />
Downloading<br />
No. Action Remarks<br />
1<br />
Before downloading software application make sure the list of<br />
Factory Settings 2-Side Trimmer is present inside the Back Cover.<br />
See Chap. 8.1<br />
2 Remove UI Cover See Chap. 4.8<br />
3 Find out the type of Tag of the machine See Chap. 2.1.1<br />
4<br />
Run the right software application for the type of machine and<br />
follow the instructions in the program.<br />
5<br />
After downloading new software it is necessary to adjust the<br />
Contrast setting (R41) of the LCD.<br />
See Chap. 7.2.2<br />
6<br />
After downloading perform an NVM reset and insert the correct<br />
NVM values according to the List in the Back Cover.<br />
See Chap. 8.1
7. PCB’S (<strong>continued</strong>)<br />
7.2 LED’S & TEST POINTS<br />
7.2.1 Motor Drive (MD6DC) PCB1 & PCB5<br />
+UNREG<br />
D15<br />
D1<br />
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This board controls the motors, encoders,<br />
switches and sensors connected to this<br />
board.<br />
Motor control is on a low level; e.g. servo<br />
and/or speed control<br />
D1: Yellow LED flashes when power is<br />
on. The flashing indicates that a<br />
program is present and functioning.<br />
Should a download fail or the 5V is<br />
missing, LED would be OFF.<br />
D2: Red LED flashes whenever<br />
information is sent or received on the<br />
Internal CAN.<br />
D15: Green LED permanently OFF. It has<br />
Fig. 7.7 no direct function in this configuration.<br />
VCC GND/PGND<br />
+UNREG: Outgoing unregulated 36V, after interlock relay. Measure between Test Point +UNREG and<br />
Test Point GND/PGND using a voltmeter. The voltage will be shown on the voltmeter unless:<br />
- Voltage is outside allowed range. Voltage will be 0V.<br />
- Machine is interlocked (i.e. the top cover is open). Voltage will be 0V.<br />
VCC: Stabilised and rectified 5V made from incoming 10V AC from transformer.<br />
- Measure between Test Point VCC and Test Point GND/PGND using a voltmeter.<br />
The voltage will be shown on the voltmeter. Range 4.9-5.1V.<br />
GND / PGND: Ground /Power Ground is the minus when measuring either unregulated 36V (+UNREG) or<br />
5V (VCC).<br />
D2
7. PCB’S (<strong>continued</strong>)<br />
7.2 LED’S & TEST POINTS (<strong>continued</strong>)<br />
7.2.2 CPU PCB6 & PCB7<br />
R41<br />
Fig. 7.8<br />
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Attention!!! Only for Standalone make sure the Mode Selection plug [6P13] (See Chap. 2.2.4) is<br />
present. Otherwise communication problems can arise.<br />
D5<br />
This board controls the machine on a higher level then the<br />
motor control boards.<br />
It also measure 36V Unreg and 24V Regulates power on the<br />
Interlock Board.<br />
D5: Yellow LED flashes when power is on. The flashing<br />
indicates that a program is present and functioning.<br />
Should a download fail or the 5V is missing, Yellow LED<br />
would be OFF.<br />
VCC: Stabilized and rectified 5V made from incoming 10V AC from transformer.<br />
Measure between Test Point VCC and Test Point GND/PGND using a voltmeter. The voltage will<br />
be shown on the voltmeter. Range 4.9-5.1V.<br />
GND: Ground is the minus when measuring 5V (VCC).<br />
R41: Trim Potentiometer for Contrast setting of the LCD.<br />
7.2.3 Softstart PCB4<br />
GND<br />
VCC<br />
This board controls the power on the machine. When the power is turned on there will<br />
be a very high current peak for a short while. To limit this current peak the Softstart<br />
PCB is used. The current peak will flow through a resistor (PTC, cold resistance 18R)<br />
and the start current is limited to 12,7A (230VAC/18R=12,7A).<br />
After about 20ms the relay will short circuit the resistor and the machine is ready to use.
7. PCB’S (<strong>continued</strong>)<br />
7.2 LED’S & TEST POINTS (<strong>continued</strong>)<br />
7.2.4 Interlock PCB3<br />
D6<br />
TP1<br />
+UNGREG +24V<br />
Fig. 7.9<br />
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This board interrupts power to the motor control boards if:<br />
- K2 is open because one of the Interlock switches is open<br />
(S3, S4, S7 or S8)<br />
- PCB6 has not released because:<br />
- 36V is outside Range<br />
- 24V is outside Range<br />
- Top Cover is open (S19 closed)<br />
- Trim Waste Bin is open (S9 closed)<br />
- K2 is not activated (contact closed)<br />
D6: Red LED is ON when unregulated 36V is present. If<br />
machine is interlocked (i.e. the Top Cover or Trim<br />
Waste Bin is open and 36V is cut off) or 36V is<br />
missing, LED is OFF.<br />
The unregulated 36V can be measured between<br />
+UNREG Test Point and PGND Test Point.<br />
D7: Red LED is ON when 24V is present. If machine is interlocked (i.e. the Top Cover or Trim Waste Bin is<br />
open) LED will still be ON.<br />
It will also be ON if 36V is present but not 24V. In such a case the 24V stabilizing circuit on the Interlock<br />
PCB would be defective. To establish that actual 24V is present, measure between +24V Test Point and<br />
PGND Test Point.<br />
D9: At power up, if all covers are closed, input power is checked to be within allowed range. If input voltage<br />
is too high or too low a fault is presented to the operator and machine will be inoperable. If the input<br />
voltage is within allowed range, and all covers are closed, the interlock relay is activated.<br />
When interlock relay is activated the LED D9 is ON. Relay will only close if Interlock switches are also<br />
closed. If an interlock relay fault is detected, that is presented to the operator and machine will be<br />
inoperable.<br />
During normal operation the LED D9 is ON when covers are closed. If a cover is open LED D9 is OFF.<br />
Note that the fault codes are only visible in operator mode.<br />
TP1: Incoming unregulated 36V, before interlock relay. Measure between Test Point TP1 and Test<br />
Point PGND using a voltmeter. The voltage will be shown on the voltmeter regardless of the<br />
voltage being outside allowed range 29-43V.<br />
+UNREG: Outgoing unregulated 36V, after interlock relay. Measure between Test Point +UNREG and<br />
Test Point PGND using a voltmeter. The voltage will be shown on the voltmeter unless:<br />
- Voltage is outside allowed range 23-43V. Voltage will be 0V.<br />
- Machine is interlocked (i.e. the top cover is open). Voltage will be 0V.<br />
+24V: Stabilised 24V made from incoming unregulated 36V, before interlock relay.<br />
Measure between Test Point +24V and Test Point PGND using a voltmeter. The voltage will<br />
be shown on the voltmeter. Range 23-25V.<br />
PGND (TP2): Power Ground is the minus when measuring either unregulated 36V (+UNREG) or 24V (+24V).<br />
8. NVM Values<br />
PGND (TP2)<br />
D7<br />
D9<br />
Contents
8.1 Current NVM Values<br />
Fig. 8.1<br />
Inside the Back Cover of the STR there is a sheet with the Factory Settings 2-Side Trimmer (Fig. 8.1).<br />
After changing any NVM Values please note the adjustments on that sheet.<br />
Before checking the current NVM Values make sure the SerialNr on the sheet matches the<br />
one on the sticker PartNr: OGMO-0000-0XXX-0000 inside the STR.<br />
Fig. 8.2 Fig. 8.3<br />
No. Action Remarks<br />
1 Enter the Service Program mode. (See Chap. 5.1)<br />
2 Use the ‘▲ / ▼’ buttons to select ‘NVM’ and press the ‘Enter’ button (See Fig. 8.2)<br />
3 Use the ‘▲ / ▼’ buttons to select the different type of ‘NVM’ Values<br />
and press the ‘Enter’ button<br />
4 Press the ‘ESC’ or ‘ ’ button to exit the Service Program mode<br />
and enter the Operator mode.<br />
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(See Fig. 8.3)
8. NVM Values (<strong>continued</strong>)<br />
8.2 Adjusting NVM Values<br />
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The following table and figure is for support of this chapter.<br />
The table explains which NVM is coupled to which Motor and what the result is of higher or lower<br />
the NVM value of the concerning Motor.<br />
Use the following table and figure to get a better view by what will happen during adjusting the<br />
NVM values in the next chapters.<br />
NVM ID Motor Position<br />
Values<br />
Min. Max. Def. Use.<br />
0 Counter Total Counter - 0 0 0 0<br />
1 Motor 6<br />
Home Position (See Fig. 8.10)<br />
+ : Smaller Finished size<br />
- : Larger Finished Size<br />
Infeed Position (See Fig. 8.10)<br />
Lower<br />
Right<br />
1800 2050 1990 1990*<br />
2 Motor 7 + : More Infeed Space<br />
- : Less Infeed Space<br />
Compress Correction (See Fig. 8.10)<br />
Left 400 500 485 485<br />
3 Motor 7 + : More Compression / Less Trimming<br />
- : Less Compression / More Trimming<br />
Infeed Position (See Fig. 8.10)<br />
Left 900 1100 1000 1000<br />
4 Motor 8 + : More Infeed Space<br />
- : Less Infeed Space<br />
Compress Correction (See Fig. 8.10)<br />
Right 400 500 485 485<br />
5 Motor 8 + : More Compression / Less Trimming<br />
- : Less Compression / More Trimming<br />
Right 900 1100 1000 1000<br />
**Recommend to use values < 2000<br />
Fig. 8.9<br />
Fig. 8.10<br />
2<br />
3<br />
1 4<br />
5
8. NVM Values (<strong>continued</strong>)<br />
8.2 Adjusting NVM Values (<strong>continued</strong>)<br />
8.2.1 NVM Booklet width correction<br />
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When switch ON the STR the Knife Blocks will move to the centre of the machine until the mechanical limit<br />
switch (S1) is activated. Than the Knife Blocks will move out of each other, release the switch. At this point<br />
the distance between the Lower Knifes x10 should be conform the NVM No. 1 Motor 6 Home Position. After<br />
that the Knife Blocks will move further to the adjusted Finished Size.<br />
It can occur that the booklet width is not conform the Finished Size on the UI display. Therefore the Booklet<br />
width, also called Finished Size, needs to be changed. By adjusting the NVM No. 1 Motor 6 Home Position<br />
the distance between the Lower Knives can be in -or decreased.<br />
Before making adjustments to the STR, make sure that the fault is not within the previous machine.<br />
Use the Service Manual of the previous machine to perform a Paper Size Check.<br />
1.Make an A3 booklet with Side Trim, measure the booklet Finished Size and compare with Finished Size<br />
on UI-display. Is the booklet Finished Size the same Finished (Trim) Size shown on the UI display?<br />
Y N<br />
Insert the measured Finished Size in the following formula:<br />
“new wished NVM No. 1 Home Position” = (“current NVM No. 1 Home Position”+<br />
(“current Finished Size on UI display” - “measured Finished Size”) x 10).<br />
When A needs to be increased, fill in the formula and higher the NVM according to the result.<br />
When B needs to be decreased, fill in the formula and lower the NVM according to the result.<br />
Change the current NVM No. 1 Motor 6 Home Position in the “new wished NVM No. 1 Motor 6<br />
Home Position.<br />
Proceed back to step 1.<br />
Proceed to chapter 8.3.2<br />
Fig. 8.11<br />
A B
8. NVM Values (<strong>continued</strong>)<br />
8.2 Adjusting NVM Values (<strong>continued</strong>)<br />
8.2.2 NVM Side Jogger correction<br />
NVM Side Jogger correction is a value that influence the positioning of the booklet.<br />
The booklet can be Side Joggered on both sides (Motor 7 and Motor 8). For each side there<br />
are two NVM values that can be adjusted: Infeed Position and Compress Correction.<br />
NVM Infeed Position<br />
NVM Infeed Position (NVM No. 2 Motor 7) & (NVM No. 4 Motor 8) is the distance<br />
between the Side Jogger and the Lower Knife in millimeters x10.<br />
This ‘default’ distance (485) is determined by moving the Side Joggers back against the<br />
mechanical switch S11 & S13 and divided by 10 (485 :10 = 48,5mm). The results is the<br />
‘home’ position of the Side Jogger in respect of the Lower Knife (See Fig. 8.9 [2] & 8.10 [4]).<br />
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Motor 7 / 8<br />
This NVM value is set to default and should never be adjusted as it is not<br />
important for the actual Finished Size.<br />
Motor 8 / 7<br />
Fig. 8.12<br />
NVM Compress Correction<br />
NVM Compress Correction (NVM No. 3 Motor 7) & (NVM No. 5 Motor 8) is an offset value to repeal<br />
mechanical deviations and used to align the booklet. A value of 1000 has been added to the NVM values<br />
because the software can not handle negative numbers. With respect to the default value there can added<br />
an offset of -100 to +100 and with that the NVM value can be adjusted to compress the booklet more or less.<br />
For example : to adjust the correct NVM Compress Correction value the distance to the Lower Knife needs to<br />
be known. For that, determine the Paper Size Width (297mm) - the Finished Size (267mm), divided by 2 =<br />
(15mm) the distance to the Lower Knife for each side and that is equal to a Side Trim of 15mm per side with<br />
an offset of zero (See Fig. 8.12).<br />
NVM Infeed Postions No. 2 & 4 are determined at 485 (48,5mm). But because of mechanical deviations<br />
NVM No. 3 & 5 are build in to prevent the Compress Correction. Theoretically the distance to the Lower<br />
Knife for the Compress Correction is 48,5mm - the Side Trim of 1 side (15mm) = 33,5mm (335).<br />
To determine if there is an Offset subtract ‘the value of 1000’ from the current NVM No. 3 or 5 (1020) = 1020<br />
- 1000 = 20. A NVM value of 1 is equals to 0,1mm, which means in this case there is an Offset of 2mm.<br />
If a Side Trim of 15mm or 150 NVM per side is wished, but due to mechanical deviations an Offset to correct<br />
is necessary. In that case there is a Trim Waste of 150 - 20 Offset = 130. Before making an adjustment the<br />
space between the Side Joggers and the booklet was corrected with an Offset of 20.<br />
Fig. 8.13 Fig. 8.14<br />
No. Action<br />
1 Enter the Service Program mode [see Chapter 5.1]<br />
2 Use the ‘▲ / ▼ buttons’ to select ‘Calibration’ and press the ‘Enter’ button.<br />
3 Choose the selected ‘Motor7 Compress Correction’ and press the ‘Enter’ button.
8. NVM Values (<strong>continued</strong>)<br />
8.2 Adjusting NVM Values (<strong>continued</strong>)<br />
8.2.2 NVM Side Jogger correction (<strong>continued</strong>)<br />
Fig. 8.15 Fig. 8.16<br />
No. Action<br />
4 Choose the selected ‘Calibration Length’ and press the ‘Enter’ button.<br />
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5 Press ‘Start’ to start the Calibration.<br />
After starting the Calibration function the Side Joggers move in and out, the Knife Blocks will<br />
move to the right Papersize, and the Transportbelt will run.<br />
A<br />
1. Send an A4 booklet of 4 sheets A3 (by preference 80grams).<br />
2. Check if the Side Joggers hits the booklet.<br />
The Side Joggers compress the booklet correctly when Side Joggering (max. 0,5mm tolerance)?<br />
Y N<br />
Add to NVM Compress Correction No.3 of Motor 7 and No.5 of Motor 8 approximately the missing<br />
distance in mm of the booklet x5 to both parameters.<br />
For Tag 6 and up: Use the ‘+ / -‘ buttons to set a NewValue(Dec) and press the ‘Save’ button.<br />
Proceed back to step 1.<br />
The booklet is NOT pressed too hard that it is bulging during Side Joggering and moves back after it is<br />
released.<br />
Y N<br />
Booklet is pressed too hard, decrease NVM No. 3 Motor 7 and No. 5 Motor 8.<br />
(Pressing the booklet to hard is so much the worse case than pressing to less)<br />
For Tag 6 and up: Use the ‘+ / -‘ buttons to set a NewValue(Dec) and press the ‘Save’ button.<br />
Proceed back to step 1.<br />
Press ’Stop’ to end the Calibration mode and ‘ ’ for exit the Calibration menu. Proceed to chapter 8.3.3
8. NVM Values (<strong>continued</strong>)<br />
8.2 Adjusting NVM Values (<strong>continued</strong>)<br />
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8.2.3 NVM Centering correction<br />
NVM Centering correction is a value that influence the centering of the booklet in de machine.<br />
The Centering correction of booklet can be adjusted with NVM Value No. 3 & 5 Compress Correction. With<br />
that both sides of the booklet are Side Joggered but the NVM values of the Side Joggers (Motor 7 and Motor<br />
8) differs.<br />
Fig. 8.17<br />
When changing a NVM value on the Right side of the machine, change the Left side of the<br />
machine the exact opposite of that value.<br />
When changing a NVM value on the Left side of the machine, change the Right side of the<br />
machine the exact opposite of that value.<br />
1. Empty the Trim Waste Bins of the STR<br />
2. Send an A4 booklet of 5 sheets A3 with a Side Trim of 267,0mm and Center Offset 0,0mm<br />
3. Measure the Trim Waste of both Bins. Are the Trim Wastes of both Bins the same Size (width)?<br />
Y N<br />
Add 5 times the difference in mm to the Compress Correction NVM value of the side that has the<br />
biggest width, subtract 5 times the difference in mm from the Compress Correction NVM value of<br />
the side that has the smallest width. (See Chap. 8.3 Fig. 8.9)<br />
The STR is fully adjusted.<br />
More Compression means less Trimming, less Compression means more Trimming<br />
Write down the adjusted NVM values on the list in the Top Cover.<br />
-<br />
+<br />
+<br />
-
8. NVM Values (<strong>continued</strong>)<br />
8.2 Adjusting NVM Values (<strong>continued</strong>)<br />
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8.2.4 NVM Stop if booklet too thick<br />
(Available from Software version SEML-0000-XXXX-V104 and up)<br />
NVM ‘Stop if booklet too thick’ is a value to set a warning for the Operator when a booklet is to thick to trim.<br />
There are 3 different warnings adjustable, which are:<br />
Value 1 (STR002) Value 2 (STR003) Value 3 (STR108)<br />
Booklet too thick! not trimmed Booklet too thick Booklet too thick<br />
(WARNING NO STOP: only (SOFT STOP: booklet (HARD STOP: booklet still<br />
message in UI display) transported outside the machine) inside the machine)<br />
Fig. 8.18 Fig. 8.19 Fig. 8. 20<br />
Change Operator Warning<br />
Fig. 8.21 Fig. 8.22<br />
Fig. 8.23<br />
No. Action<br />
1 Enter the Service Program mode [see Chapter 5.1]<br />
2 Use the ‘▲ / ▼’ buttons to select ‘NVM’ and press the ‘Enter’ button.<br />
3 Use the ‘▲ / ▼’ buttons to select NVM 6 Stop if booklet too thick and press the ‘Change’ button.<br />
4 Use the ‘+ / -‘ buttons to set a NewValue(Dec) 1, 2 or 3 (See options above) and press the ‘OK’<br />
button.<br />
5 Press the ‘ESC’ or ‘ ’ button to exit the Service Program mode and enter the Operator mode.
8. NVM Values (<strong>continued</strong>)<br />
8.3 Reset NVM Values<br />
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If minor logic problems arise the NVM Reset procedure can be initiated. All data in the PCB will be cleared<br />
except the number of the Total Counter.<br />
Fig. 8.24 Fig. 8.25<br />
No. Action Remarks<br />
1 Enter the Service Program mode. (See Chap. 5.1)<br />
2 Use the ‘▲ / ▼’ buttons to select ‘NVM’ and press the ‘Enter’ button (See Fig. 8.24)<br />
3 Press the ‘ResetAll’ button, insert the correct NVM values according<br />
to the list of Factory Settings 2-Side Trimmer in the Back Cover,<br />
and confirm with the ‘Yes’ button.<br />
4 Press the ‘ESC’ or ‘ ’ button to exit the Service Program mode<br />
and enter the Operator mode.<br />
(See Fig. 8.25) See Chap. 8.1
9. Maintenance<br />
9.1 Preventive maintenance table<br />
If any of the checkpoints area’s or other parts show indication of wear at any point, replace the parts.<br />
When parts need a new lubrication, clean the surface if necessary before applying a new lubricant.<br />
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The STR requires a minimum of 400mm of additional floor space on the back side for installation, operation<br />
and maintenance.<br />
Run the Checkpoints STR at an interval of 250.000 sets.<br />
Symbol key: C = Cleaning, I = Inspect, L = Lubricate, R = Replace, W = Wipe<br />
Checkpoints area’s STR after 250.000 sets Checkpoints NOTE<br />
Paper path C Dry Cloth / Brush<br />
Sensors C Dry Cloth / Brush<br />
Transport module I Inspect<br />
Upper belt (1x) W Moister Cloth<br />
Lower belt (3x) W Moister Cloth<br />
Trim knives I Inspect<br />
Knives (L+R) I Inspect<br />
Knife guiding blocks L / I Grease<br />
Protection plate knife guidance L / I Grease<br />
Knife chains L Oil<br />
Knife sprockets L Oil<br />
Side Jogger guidance L Grease
9. Maintenance (<strong>continued</strong>)<br />
9.2 Schematics<br />
9.2.1 DTEO-0000-0121-0000<br />
9.2.2 DTEO-0000-0142-0000<br />
9.2.3 DTEO-0000-0143-0000<br />
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10. Technical Information<br />
Capabilities:<br />
Compatibility: Online STR:<br />
Capacity: Up to 25 sheets<br />
(80 g/m 2 , 100 pages booklet)<br />
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Electrical:<br />
Contents<br />
Power source: from Booklet Maker<br />
50Hz: 220/230V, 2.0A<br />
60Hz: 220/230V, 2.0A<br />
Physical:<br />
Operational On Pallet in box<br />
Height ≈855 mm 1440 mm<br />
Width 740 mm 760 mm<br />
Depth 700 mm 1410 mm<br />
Weight ≈215 Kg ≈257 Kg<br />
60Hz: 100/110/120/127V, 4.0A<br />
(upon request)<br />
The 2-Side Trimmer should only be connected<br />
to an approved electrical system which is rated<br />
at a maximum of 16A and which is protected by<br />
circuit breakers.<br />
Booklet specifications<br />
before trimming: bypass: trimmed:<br />
Minimum booklet height: 204 mm 150 mm 200 mm<br />
Maximum booklet height: 340 mm 320 mm 320 mm<br />
Maximum booklet thickness 5 mm<br />
Technical specifications<br />
Speed 1800 booklets/hour<br />
Trimming size (min-max) 2mm - 35mm each side 4mm - 70mm together<br />
Paper Weight (min-max) 60 g/m2 - 300 g/m2 Note: on booklets from about<br />
20 sheets or more, always use<br />
coversheets from 120 g/m 2 or<br />
higher to prevent possible<br />
deviations (like crinkles) on the<br />
booklet.<br />
A-symmetrical trim (min-max) ±15mm<br />
Input / Output sheets Booklet Width (X) from 50 mm Note: Heights between 320<br />
up to 245 mm<br />
mm and 340 mm must be<br />
Booklets Height (Z) 204 mm trimmed back to 320mm or<br />
up to 340 mm<br />
shorter.<br />
Booklet Staple Clearance from<br />
top/bottom (minimal)<br />
40mm<br />
Noise Level (max) 70dB
PAGE INTENTIONALLY BLANK<br />
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