Duplo EX2000 Service Manual
Duplo Express Sealer EX-2000
Service Manual
Provided By
http://www.MyBinding.com
http://www.MyBindingBlog.com
Introduction Symbols and Notations in this manual Safety precautions Various symbols and pictures are used in this manual and on the stickers affixed to the machine. These symbols and pictures provide warnings and instructions to prevent danger to you or other personnel, and to prevent damage to office property. The meanings of these symbols and pictures are explained below.
WARNING Indicates a high degree of potential danger. Ignoring the warning may result in death or serious injury of personnel.
CAUTION Indicates a medium degree of potential danger. Ignoring the caution may result in injury of personnel or damage to properties.
Examples of pictorial symbols A circle with a line through it indicates a prohibited action. The particular act prohibited is indicated by a picture inside the circle. ( In the example on the right indicates ‘disassembly is prohibited.’
●
A black disc indicates an instruction , or sometimes a prohibited action. The instruction itself is indicated by pictorial symbols drawn in white on the disc. ( In the example on the right indicates ‘Remove the plug from the outlet.’
Other Notations IMPORTANT
Notes on faulty operation/maintenance which can damage products or disturb its performance.
REF.
Information in regards to the performance of the product, operation or maintenance.
1
2
3
Contents
1. 2. 3. 4. 5. 6. 7. 8. 9.
Introduction ････････････････････････････････････････････････････････････････････････ Specifications ･････････････････････････････････････････････････････････････････････ Parts names and their functions ･･････････････････････････････････････････････････ Paper flow and operating principle ････････････････････････････････････････････････ Operating sequence ･･･････････････････････････････････････････････････････････････ Circuits and their operation ･･･････････････････････････････････････････････････････ Maintenance and adjustments ････････････････････････････････････････････････････ HELP mode ････････････････････････････････････････････････････････････････････････ Error message displays ･･･････････････････････････････････････････････････････････ Electrical parts･････････････････････････････････････････････････････････････････････
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1 5 6 7 8 8 11 20 23 26
1. Specifications No.
Item
Specification
1 Type
Desktop
2 Model name
EX-2000
３ Paper size ４ Finished size
５ Paper type
６ Processing speed ７ Feed system ８ Feed capacity ９ Fold types
Length：279.4ｍｍ (11”) - 355.6mm (14”) Width ：210mm - 215.9mm (8.5”) Length： 93.1mm - １48.5mm Width ： 210mm - 215.9mm (8.5”) 24lb（90g/㎡） - 32lb（120g/㎡） Envelop paper with pressure sensitive adhesive along the edges of the front * Do not use envelop paper with pressure sensitive adhesive applied overall. 7000 sheets/hour （FAST） 8.5”×11” Z-fold envelop 5000 sheets/hour （SLOW） Friction feed system based on rubber rollers and paper separation plate 200 Z-fold (accordion fold) envelopes (thickness: 28lb) V-fold, C-fold, Z-fold, EZ-fold, EC-fold
10 Fold size
1st panel 2nd panel
11 Stacker type
Gravity stacker
12 Stacker capacity
200 Z-fold (accordion fold) envelopes (thickness: 28lb)
60mm - 266.7mm 60mm – 118.5mm
Test operation Paper detection JAM detection for all paper paths １３
Functions & safety Cover interlock system Manual feed Double feed detection Speed selection Batch count
１4 Dimensions
[In use] 756mm（D）×701ｍｍ（W）×533（H） [Folded] 633ｍｍ（D）×465ｍｍ（W）×403（H）
１5 Weight
54kg (folder: 22.5kg, sealer: 31.5kg)
１6 Power source
AC115Ｖ（±10％） 60Hz 3A
１7 Power consumption
330W
18
Operating
temperature 19 Operating humidity
Remarks
10 – 30℃ 40 – 70% (No condensation)
Notice: Specifications are subject to change for improvement without notice.
5
Under operating temperature
2. Parts names and their functions 7 1
3
2
5 ９
4 8
6
13
10
11
12 No. 1
Function Adjusts feed pressure according to paper thickness. Normally set to “Standard”. Makes smooth paper transport by adjusting the guides to the paper size. Adjusts double feed detection according to paper thickness.
4
Name Feed pressure adjuster lever Paper feed guides Double feed detection adjuster knob Paper set lever
5
Control panel
Use keys for operation. The display shows the current operational status.
6
Power switch
Press the “I” to turn on and “○” to turn off.
7
Folding tray 1
Used for all foldings (Z-fold, C-fold, V-fold)
8
Folding tray 2
Used for Z-fold and C-fold.
9
Support tray
Used when setting paper.
10
Handle slot
Insert the handle to remove jammed paper or clean the rubber rollers.
11
Stacker stopper
Adjust this stopper according to ejected paper.
12
Stacker guide
Adjust these guides according to ejected paper.
13
Safety cover
Open this cover to adjust the transport guide or to remove jammed paper.
2 3
Lower this lever before loading paper and raise it to start operation.
6
Install the turn guide for V-fold.
3. Paper flow and operating principle 3-1 Folding section PPS sensor 1 (light receiving) Support tray
Paper feed ring
Parts name Folding roller 1 Double feed detection roller Folding tray 1
Paper tray Folding roller 3 PPS sensor 2 (light receiving) Ejection roller Paper separator unit PPS sensor 1 (light emitting)）
Folding roller 2 Folding roller 4
PPS sensor 2 (light emitting)
Folding tray 2
1． Papers loaded on the feed tray are separated to 1
Double feed detection roller
sheet by the separator unit when being fed by the paper feed ring. (The timing for feeding the paper is controlled by the PPS 1 which senses paper flow.)
2． In the double feed detecting section, the paper presses up the upper double feed detection roller when it passes between the rollers. When the upper roller is pressed up higher than reference position, double feed is detected and the machine stops.
PPS sensor 1 Paper tray
(Error message ‘DOUBLE FEED’ will appear in the display.)
Paper Stopper Folding tray 1
3． The paper passed through the double feed detection
Folding roller 1
section is fed to the folding tray 1 by the folding rollers 1 and 2, and stops at the stopper.
The stopped paper
sags and is fed to the path between the folding rollers 2 and 3, and then is fed to the folding tray 2. Folding roller 2 7
Folding roller 3
4． The paper fed to the folding tray 2 sags by bumping the stopper as well as the flow in the folding tray 1,
Folding roller 2
Folding roller 3
and is fed to the path between the folding rollers 3 and 4, and then is fed to the sealer section by the ejection roller.
Folding tray 2
(When V-fold is executed, the paper is fed directly to the path between the folding rollers 3 and 4 from
Stopper
Folding roller 4
the folding tray 1 by leading with the turn guide.)
3-2 Sealer section Parts names
Pressure roller (upper) Bracket F (upper) PPS sensor 3 (light receiving) Stopper
Roller
Bracket F (lower)
Feed roller
PPS sensor 3 (light emitting) Pressure roller (lower) Bracket F (upper)
1. The paper fed to the sealer section touches the stopper, and is fed to the pressure roller section by the feed rollers and roller. Roller
2. The temporary sealed part in the folding section of the paper fed is peeled off by the bracket F (upper and lower)
Pressure roller (upper)
installed adjacent to the feed roller, and then is fed to the pressure roller section. 3. The paper is applied by strong pressure between the pressure rollers, and pressure sensitive adhesive
Feed roller
Pressure roller (lower)
parts are adhered. Bracket F (lower)
8
4. Operating sequence
* Both motors stop 1 second after the PPS3 sensor detects photopassing (ejecting paper).
5. Circuits and their operation Paper empty SW circuit A sensor is installed on the feed tray and detects paper empty.
PPS1 circuit PPS1 is installed in the paper feeding section, and detects that the paper is properly fed.
PPS2 circuit PPS2 is installed in front of the eject roller, and detects that the paper is ejected.
PPS3 circuit PPS3 is installed at the back of the feed roller, and detects that the paper is properly fed.
10
6. Maintenance and adjustments ●Exterior Side cover L Sealer cover 2
Sealer cover 1 Side cover R (lower) Side cover R assy
* Remove the folding plate, support tray, stacker guides, and the stacker stopper before starting maintenance. ●Removing covers Photograph 1
[Side cover R assy] Remove the 4 screws in the circles in the photographes 1, 2, and 3.
Disconnect the connectors (yellow, yellow, white,
white) interlock swtich connecting to the machine, and then remove the cover R.
Interlock switch connector
Photograph 2
Photograph 4
[Side cover L] Remove the 2 screws in the circles in the phototgraph 4. Remove the side cover L with lifting up.
Refer to the photograph 5 for installing the side cover L. Fit the stay hole at the lower part of the side cover L on the screw of the rubber foot at the lower part of the frame.
(2 points)
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Photograph 5
Photograph 3
[Sealer cover 1] Remove the 3 screws (3mm taptight) indicated in the right photograph and remove the cover toward you.
[Sealer cover 2] Remove the 3 screws in the circles in the right photographes, Disconnect the connectors (yellow, yellow, white, white) of the interlock switch connecting to the machine, and then remove the sealer cover 2 with lifting up.
Interlock switch connector ●Maintenance [Folder side] Paper feed section Slide the paper feed ring assy in the direction of the arrow in the right photograph.
After joint part is released, extend the paper feed guides, and pull out the joint toward you.
Loosen the set screw and remove the paper feed ring. (3 pcs.)
②Take out to the direction of the arrow.
For installing, follow the reverse procedure. ●Tighten the set screw so that it fits the counterbore of the paper feed shaft. ●Paper feed rings should be replaced as a set (3 pcs.). （Mixture of old ring and new one may cause skew.） 12
①Loosen the screw.
Replacing the main PCB Screw
Remove the 10 connectors and the 4 screws、
Connector
and then remove the main PCB.
Main PCB
Replacing the main motor Remove the 4 screws indicated in the right photograph, and remove the rear cover.
Rear cover
Remove the 4 nuts indicated in the photograph 1, and remove the main motor toward the arrow in the photograph 2.
Photograph 1 Caution should be taken for the belt tension when installing the motor. (Adjust the motor position by applying load of 300g to the midpoint of the belt between the pulleys so that a slack (3mm±1mm) can be made.) 300ｇ/3mm
13
Photograph 2
Replacing the flat belt Remove the 3 screws indicated in the photograph (left side), and then remove the bracket. Bracket Take out the paper feed clutch from the
Paper feed clutch
bush in the photograph (right side).
Loosen the 2 screws indicated in the right photograph to move the tension roller, and then remove the belt.
Tension roller For installing the belt, follow the reverse procedure. (Adjust the position of the tension roller by applying load of 300g to the indicated place in the right photograph so that a slack
300ｇ/1mm
(1mm±0.5mm) can be made.)
[Sealer side] Replacing motor and electrical parts 1. Remove the timing belt for driving conveyer.
(no adjustment)
2. Loosen the 4 screws in the circles in the photograph 1, and remove the timing belt for driving roller 3. Remove the C ring and then remove the pulley unit (idler) in the photograph 1. 4. Remove the 4 screws in the squres in the photographs1 and 2. Photograph 1 Timing belt for driving conveyer
Photograph 2
Pulley unit (idler) Roller driving belt
14
5. Remove the encoder sensor and PPS3 cable, and then take out the cabinet 2 by lifting it up as shown in the right photograph. Cabinet 2
Cabinet 1
6. Inside of the cabinet 1 is as shown in the right photograph.
Circuit protector Capacitor
(Refer to the circuit diagram on page 28.)
AC gear motor
Fan motor
SSR
Power relay
Replacing conveyer belt 1. Remove the 4 screws indicated in the photograph 1
Photograph 1
to remove the cabinet 2 and the conveyer unit.
2. Remove the screw in the circle in the photograph 2 to pull out the shaft.
Photograph 2
Remove the stopper. (Do not lose the plastic balls (2 pcs.) by the side of thumb screw and the sliders (2 pcs.) at both sides.) 3. Remove the screws in the squres in the photographs 2 and 3, and then remove the upper cover.
Photograph 3
4. Remove the screws in the circles in the photograph 4, and then remove the pipes. Remove the bearing stopper installing the roller, and then remove the roller. 5. Replace the belt.
After replacing the belt,
Photograph 4
Install the roller and the pipes. Adjust the belt tenstion with the tension in the squres. (A slack should be 1±0.5mm when pulling up the place indicated with a blue arrow by the force of 400g.) 15
Roller
Pipes
Replacing scraper Remove the 4 screws indicated in the right photograph, and then remove the both bracket Rs. (Both the upper bracket R and the lower one are the same.)
Remove the screws indicated in the right photograph, and then replace the scraper. After replacing it, install the scraper so that 7mm
it appears by 7mm from the edge of the bracket.
16
[Adjustments] Adjusting double feed detection unit Parts names
Folding roller 1
Photo sensor
Hole Detection roller (upper)
Lever Eccentric pin
Fulcrum Folding roller 2
Detection roller (lower) Paper
1. Turn the eccentric pin until the gap between the upper and lower detection rollers is at the maximum setting. Insert a sheet of 70kg (approximately) paper between the detectio rollers.
Eccentric pin Paper Supporting point
2. Turn the eccentric pin until it touches the hole, Then fasten it with the screw. Enlarged veiw
○
× 3. Adjustment completes when the lever does not move by running a sheet of paper between the detection rollers and it moves by running 2 sheets of paper.
17
There should be no gap.
Adjusting folding roller Bearing holder
1. Loosen the 2 screws holding the bearing holder of each roller. Slide the folding rollers 1 and 3 along the elongate hole taking the roller 2 as reference so that these rollers are pressed up the roller 2. 2. Adjust the folding roller 4 taking the folding roller 3 adjusted in the step 1 as reference. * Each roller should be symmetrical to the left and right, and there should be no gap between rollers. (Asymmetrical roller pressure causes snaking or wrinkling.)
* After adjustment, a roller should rotate without flat belt and all rollers should drive together. Screw shaft
Adjusting pressure of pressure roller 1. Turn the screw shaft for adjusting pressure until the top edge of the shaft touches the pin top.
Pin
2. Turn the screw shaft clockwise with a handle for 180゜from the contact position in the step 1.
Belleville spring
(symmetrical to the left and right) * Turning the screw shaft clockwise increases the pressure. * Turning the screw shaft counterclockwise
Care should taken for installed direction of belleville spring.
decreases the pressure. Note: Asymmetrical roller pressure causes snaking or uneven pressurizing.
③ Adjusting interlock switc Circuit diagram
①
①
Handle slot, sealer side
②
Safety cover
③
Folding tray 1
④
Folding tray 2
⑤
Handle slot, folder side
⑤ ④
* 2 pcs. of micro switch (5V, 24V) are set at each 5 interlock switches.
②
The machine operates only when all the micro switches are ON. 18
7.HELP Mode ＜ＨＥＬＰ Mode List＞ HELP Mode No.
Description
Remarks
H-00
Rom version display
H-01
Motor check
H-02
Sensor & switch check
H-03
Motor & clutch check
H-04
Not used
H-05
Error & jam counter
H-06
RAM initialization
H-07
Setting double feed detecting timing
H-08
Total counter display
H-09
Not used
H-10
Not used
H-11
Not used
H-12
Selecting language for display
H-13
Not used
H-14
Not used
* Operation Check Operation of single motor, certain continuous operation, and operation of electrical parts can be executed. In this mode, operation is executed by a single motor to be checked. the status or position of related parts and mechanism.
Care should be taken for
Also, care should be taken not to put
your hands or fingers in the moving parts.
WARNING ! Your hands or fingers may get caught in The machinery and injured.
19
Accessing HELP mode 1. Turn the power switch ON while pressing the JOG key and MODE key. 2. A buzzer sounds and the HELP mode is displayed. 3. Select HELP mode no. by pressing the JOG key or MODE key. 4. Press the START key to enter the HELP mode that you selected in the step 3.
If you want to return to
the mode selection display, press the STOP key.
[ＨＥＬＰ Mode Description] 1. H-00： ROM version display: The ROM version of the main PCB unit is displayed. Access the HELP mode H-00, and the press the START key. H-00:
V*.**
2. H-01： Motor check: Operation check of the folding motor and sealer motor. Access the HELP mode H-01, and the press the START key.
The folding motor and sealer motor will
rotate. MOTOR RUN
3. H-02： Motor & clutch check: Operation check of the folding motor and feed clutch. Access the HELP mode H-02, and the press the START key.
The folding motor will rotate.
The feed clutch will be ON while the TEST key is pressed. TEST ->CLUTCH ON
4. H-03： Sensor & switch check: Operation check of the sensors and switches Access the HELP mode H-03, and the press the START key. 0000 0000 0000 ABCD EFGH IJKL A： Paper empty sensor (paper 0, no paper 1) B： Folder encoder (photopassing 0, photointerrupting 1) Ｃ： Sealer encoder sensor (photopassing 0,
photointerrupting 1)
Ｄ：PPS1 (photopassing 0,
photointerrupting 1)
Ｅ： PPS2(photopassing 0,
photointerrupting 1)
Ｆ： Folding handle cover SW (ON 0, OFF 1) Ｇ：PPS3 (photopassing 1, photointerrupting 0) H： Folding plate SW(ON 0, OFF 1) Ｉ： Sealer handle cover SW (ON 0, OFF 1) Ｊ： Double feed detecting sensor (photopassing 0,
photointerrupting 1)
K： Sealer cover SW (ON 0, OFF 1) L： Not used 20
5. H-04： Not used.
6. H-05： Error & jam counter: Checking number of error occurrences Access the HELP mode H-05, and the press the START key. Press the JOG key to check the item. Press the MODE key for 2 seconds to clear the counter. (Each error can be counted up to 9,999.) FEED MISS
****
F.JAM1
****
F.JAM2
****
F.M.LOCK
****
CONV.JAM
****
S.JAM
****
S.M.LOCK
****
DBL JAM
****
7. H-06： RAM initialization Access the HELP mode H-06, and the press the START key. The MODE key and JOG key.
The entire RAM is initialized by pressing
(The machine will return to factory setting.)
MODE + JOG
8.H-07： Setting double feed detecting timing: Chattering time of the double feed detecting sensor is set. Access the HELP mode H-07, and the press the START key. Press the MODE key to select the A to D. Press the JOG key to select 0 or 1. Press the START key to set the setting. Press the STOP key to cancel the setting. (Factory setting: 0011) A:0 B:0 C:1 D:1 0000：8ms、0001：16ms、0010：24ms、0011：32ms、0100：40ms 0101：48ms、0110：56ms、0111：64ms、1000：72ms、1001：80ms 1010：88ms、1011：96ms、1100：104ms、1101：112ms、1110：120ms 1111：128ms
9.H-08： Total counter display Access the HELP mode H-08, and the press the START key.
Total counter will appear on the
display. TOTAL : ******** It can display up to 99999999. (When it exceeds 99999999, it will start with 0 again.)
10. H-09： Not used.
11. H-10： Not used. 21
12. H-11： Not used.
13. H-12： Selecting language for display Access the HELP mode H-12, and the press the START key. A:0 B:0 C:0 D:0 （HELP6 RAM initialization: 0001） 0000
English, 0001 Japanese
14. H-13： Not used.
15. H-14： Not used.
22
8. Error Massage Displays 1. COVER OPEN (without warning beep)
COVER OPEN Status: The safety cover is open. The safety cover is opened during operation Solution: Close the safety cover.
2. NO PAPER (without warning beep)
NO PAPER Status: The START key or TEST key is pressed with no paper on the feed tray. Solution: 1. Load paper. 2. Press the STOP/C key.
3. MISS FEED (with warning beep)
MISS FEED Status: 1. While the paper feed clutch driving signal is lit, the PPS1 cannot detect the paper edge. 2. The PPS1 keeps detecting photointerrupting status for a certain period of time. Solution: 1. Remove jammed paper. 2. Press the STOP/C key.
4. FOLDER JAM 1 (with warning beep)
FOLDER JAM 1 Status: The PPS1 detects the paper, but the PPS2 does not detect it. Solution: 1. Remove jammed paper. 2. Press the STOP/C key.
5. FOLDER JAM 2 (with warning beep)
FOLDER JAM 2 Status: The PPS2 detects the paper and continues detecting. Solution: 1. Remove jammed paper. 2. Press the STOP/C key.
23
6. MOTOR LOCK (with warning beep)
F.MOTOR LOCK
RESET BREAKER
Status: The encoder sensor keeps detecting photointerrupting or photopassing for a certain period of time, and the folding motor does not run. Solution A: 1. Remove jammed paper. 2. Press the STOP/C key. Solution B: Press the breaker in the back of the folding tray 2.
7. CONVEYER JAM (with warning beep)
CONVEYER JAM Status: The PPS2 detects the paper, but the PPS3 does not detect it. Solution: 1. Remove jammed paper. 2. Press the STOP/C key.
8. SEALER JAM (with warning beep)
SEALER JAM Status: 1. The PPS3 keeps detecting the paper. 2. The first paper does not pass through the PPS1, PPS2, and PPS3 in order.
(This happens
When normal operation is executed without removing the paper in the cross conveyer after Folding test.) Solution: 1. Remove jammed paper. 2. Press the STOP/C key.
9. S. MOTOR LOCK (with warning beep)
S.MOTOR LOCK
RESET BREAKER
Status: The encoder sensor keeps detecting photointerrupting or photopassing for a certain period of time, and the sealer motor does not run. Solution A: 1. Remove jammed paper. 2. Press the STOP/C key. Solution B: Press the breaker above the power switch.
10. DOUBLE FEED (with warning beep)
DOUBLE FEED Status: The double feed sensor detects photointerrupting for a certain period of time during operation. Solution: 1. Remove jammed paper. 2. Press the STOP/C key. 24
11. REMOVE PAPER
REMOVE PAPER Status: The START, TEST or JOG key was pressed when any of PPS detects photo interrupting. (This message appears after folding test only when folding test is executed.) Solution A: 1. Remove jammed paper. 2. Press the STOP/C key. Solution B: Open the sealer cover or press the STOP key.
25
9. Electrical parts Connector layout ①Main PCB unit
②Switching power supply PCB unit
③Memory PCB unit
26
Circuit diagram
2005.02 28
Service Manual
Provided By
http://www.MyBinding.com
http://www.MyBindingBlog.com
Introduction Symbols and Notations in this manual Safety precautions Various symbols and pictures are used in this manual and on the stickers affixed to the machine. These symbols and pictures provide warnings and instructions to prevent danger to you or other personnel, and to prevent damage to office property. The meanings of these symbols and pictures are explained below.
WARNING Indicates a high degree of potential danger. Ignoring the warning may result in death or serious injury of personnel.
CAUTION Indicates a medium degree of potential danger. Ignoring the caution may result in injury of personnel or damage to properties.
Examples of pictorial symbols A circle with a line through it indicates a prohibited action. The particular act prohibited is indicated by a picture inside the circle. ( In the example on the right indicates ‘disassembly is prohibited.’
●
A black disc indicates an instruction , or sometimes a prohibited action. The instruction itself is indicated by pictorial symbols drawn in white on the disc. ( In the example on the right indicates ‘Remove the plug from the outlet.’
Other Notations IMPORTANT
Notes on faulty operation/maintenance which can damage products or disturb its performance.
REF.
Information in regards to the performance of the product, operation or maintenance.
1
2
3
Contents
1. 2. 3. 4. 5. 6. 7. 8. 9.
Introduction ････････････････････････････････････････････････････････････････････････ Specifications ･････････････････････････････････････････････････････････････････････ Parts names and their functions ･･････････････････････････････････････････････････ Paper flow and operating principle ････････････････････････････････････････････････ Operating sequence ･･･････････････････････････････････････････････････････････････ Circuits and their operation ･･･････････････････････････････････････････････････････ Maintenance and adjustments ････････････････････････････････････････････････････ HELP mode ････････････････････････････････････････････････････････････････････････ Error message displays ･･･････････････････････････････････････････････････････････ Electrical parts･････････････････････････････････････････････････････････････････････
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1 5 6 7 8 8 11 20 23 26
1. Specifications No.
Item
Specification
1 Type
Desktop
2 Model name
EX-2000
３ Paper size ４ Finished size
５ Paper type
６ Processing speed ７ Feed system ８ Feed capacity ９ Fold types
Length：279.4ｍｍ (11”) - 355.6mm (14”) Width ：210mm - 215.9mm (8.5”) Length： 93.1mm - １48.5mm Width ： 210mm - 215.9mm (8.5”) 24lb（90g/㎡） - 32lb（120g/㎡） Envelop paper with pressure sensitive adhesive along the edges of the front * Do not use envelop paper with pressure sensitive adhesive applied overall. 7000 sheets/hour （FAST） 8.5”×11” Z-fold envelop 5000 sheets/hour （SLOW） Friction feed system based on rubber rollers and paper separation plate 200 Z-fold (accordion fold) envelopes (thickness: 28lb) V-fold, C-fold, Z-fold, EZ-fold, EC-fold
10 Fold size
1st panel 2nd panel
11 Stacker type
Gravity stacker
12 Stacker capacity
200 Z-fold (accordion fold) envelopes (thickness: 28lb)
60mm - 266.7mm 60mm – 118.5mm
Test operation Paper detection JAM detection for all paper paths １３
Functions & safety Cover interlock system Manual feed Double feed detection Speed selection Batch count
１4 Dimensions
[In use] 756mm（D）×701ｍｍ（W）×533（H） [Folded] 633ｍｍ（D）×465ｍｍ（W）×403（H）
１5 Weight
54kg (folder: 22.5kg, sealer: 31.5kg)
１6 Power source
AC115Ｖ（±10％） 60Hz 3A
１7 Power consumption
330W
18
Operating
temperature 19 Operating humidity
Remarks
10 – 30℃ 40 – 70% (No condensation)
Notice: Specifications are subject to change for improvement without notice.
5
Under operating temperature
2. Parts names and their functions 7 1
3
2
5 ９
4 8
6
13
10
11
12 No. 1
Function Adjusts feed pressure according to paper thickness. Normally set to “Standard”. Makes smooth paper transport by adjusting the guides to the paper size. Adjusts double feed detection according to paper thickness.
4
Name Feed pressure adjuster lever Paper feed guides Double feed detection adjuster knob Paper set lever
5
Control panel
Use keys for operation. The display shows the current operational status.
6
Power switch
Press the “I” to turn on and “○” to turn off.
7
Folding tray 1
Used for all foldings (Z-fold, C-fold, V-fold)
8
Folding tray 2
Used for Z-fold and C-fold.
9
Support tray
Used when setting paper.
10
Handle slot
Insert the handle to remove jammed paper or clean the rubber rollers.
11
Stacker stopper
Adjust this stopper according to ejected paper.
12
Stacker guide
Adjust these guides according to ejected paper.
13
Safety cover
Open this cover to adjust the transport guide or to remove jammed paper.
2 3
Lower this lever before loading paper and raise it to start operation.
6
Install the turn guide for V-fold.
3. Paper flow and operating principle 3-1 Folding section PPS sensor 1 (light receiving) Support tray
Paper feed ring
Parts name Folding roller 1 Double feed detection roller Folding tray 1
Paper tray Folding roller 3 PPS sensor 2 (light receiving) Ejection roller Paper separator unit PPS sensor 1 (light emitting)）
Folding roller 2 Folding roller 4
PPS sensor 2 (light emitting)
Folding tray 2
1． Papers loaded on the feed tray are separated to 1
Double feed detection roller
sheet by the separator unit when being fed by the paper feed ring. (The timing for feeding the paper is controlled by the PPS 1 which senses paper flow.)
2． In the double feed detecting section, the paper presses up the upper double feed detection roller when it passes between the rollers. When the upper roller is pressed up higher than reference position, double feed is detected and the machine stops.
PPS sensor 1 Paper tray
(Error message ‘DOUBLE FEED’ will appear in the display.)
Paper Stopper Folding tray 1
3． The paper passed through the double feed detection
Folding roller 1
section is fed to the folding tray 1 by the folding rollers 1 and 2, and stops at the stopper.
The stopped paper
sags and is fed to the path between the folding rollers 2 and 3, and then is fed to the folding tray 2. Folding roller 2 7
Folding roller 3
4． The paper fed to the folding tray 2 sags by bumping the stopper as well as the flow in the folding tray 1,
Folding roller 2
Folding roller 3
and is fed to the path between the folding rollers 3 and 4, and then is fed to the sealer section by the ejection roller.
Folding tray 2
(When V-fold is executed, the paper is fed directly to the path between the folding rollers 3 and 4 from
Stopper
Folding roller 4
the folding tray 1 by leading with the turn guide.)
3-2 Sealer section Parts names
Pressure roller (upper) Bracket F (upper) PPS sensor 3 (light receiving) Stopper
Roller
Bracket F (lower)
Feed roller
PPS sensor 3 (light emitting) Pressure roller (lower) Bracket F (upper)
1. The paper fed to the sealer section touches the stopper, and is fed to the pressure roller section by the feed rollers and roller. Roller
2. The temporary sealed part in the folding section of the paper fed is peeled off by the bracket F (upper and lower)
Pressure roller (upper)
installed adjacent to the feed roller, and then is fed to the pressure roller section. 3. The paper is applied by strong pressure between the pressure rollers, and pressure sensitive adhesive
Feed roller
Pressure roller (lower)
parts are adhered. Bracket F (lower)
8
4. Operating sequence
* Both motors stop 1 second after the PPS3 sensor detects photopassing (ejecting paper).
5. Circuits and their operation Paper empty SW circuit A sensor is installed on the feed tray and detects paper empty.
PPS1 circuit PPS1 is installed in the paper feeding section, and detects that the paper is properly fed.
PPS2 circuit PPS2 is installed in front of the eject roller, and detects that the paper is ejected.
PPS3 circuit PPS3 is installed at the back of the feed roller, and detects that the paper is properly fed.
10
6. Maintenance and adjustments ●Exterior Side cover L Sealer cover 2
Sealer cover 1 Side cover R (lower) Side cover R assy
* Remove the folding plate, support tray, stacker guides, and the stacker stopper before starting maintenance. ●Removing covers Photograph 1
[Side cover R assy] Remove the 4 screws in the circles in the photographes 1, 2, and 3.
Disconnect the connectors (yellow, yellow, white,
white) interlock swtich connecting to the machine, and then remove the cover R.
Interlock switch connector
Photograph 2
Photograph 4
[Side cover L] Remove the 2 screws in the circles in the phototgraph 4. Remove the side cover L with lifting up.
Refer to the photograph 5 for installing the side cover L. Fit the stay hole at the lower part of the side cover L on the screw of the rubber foot at the lower part of the frame.
(2 points)
11
Photograph 5
Photograph 3
[Sealer cover 1] Remove the 3 screws (3mm taptight) indicated in the right photograph and remove the cover toward you.
[Sealer cover 2] Remove the 3 screws in the circles in the right photographes, Disconnect the connectors (yellow, yellow, white, white) of the interlock switch connecting to the machine, and then remove the sealer cover 2 with lifting up.
Interlock switch connector ●Maintenance [Folder side] Paper feed section Slide the paper feed ring assy in the direction of the arrow in the right photograph.
After joint part is released, extend the paper feed guides, and pull out the joint toward you.
Loosen the set screw and remove the paper feed ring. (3 pcs.)
②Take out to the direction of the arrow.
For installing, follow the reverse procedure. ●Tighten the set screw so that it fits the counterbore of the paper feed shaft. ●Paper feed rings should be replaced as a set (3 pcs.). （Mixture of old ring and new one may cause skew.） 12
①Loosen the screw.
Replacing the main PCB Screw
Remove the 10 connectors and the 4 screws、
Connector
and then remove the main PCB.
Main PCB
Replacing the main motor Remove the 4 screws indicated in the right photograph, and remove the rear cover.
Rear cover
Remove the 4 nuts indicated in the photograph 1, and remove the main motor toward the arrow in the photograph 2.
Photograph 1 Caution should be taken for the belt tension when installing the motor. (Adjust the motor position by applying load of 300g to the midpoint of the belt between the pulleys so that a slack (3mm±1mm) can be made.) 300ｇ/3mm
13
Photograph 2
Replacing the flat belt Remove the 3 screws indicated in the photograph (left side), and then remove the bracket. Bracket Take out the paper feed clutch from the
Paper feed clutch
bush in the photograph (right side).
Loosen the 2 screws indicated in the right photograph to move the tension roller, and then remove the belt.
Tension roller For installing the belt, follow the reverse procedure. (Adjust the position of the tension roller by applying load of 300g to the indicated place in the right photograph so that a slack
300ｇ/1mm
(1mm±0.5mm) can be made.)
[Sealer side] Replacing motor and electrical parts 1. Remove the timing belt for driving conveyer.
(no adjustment)
2. Loosen the 4 screws in the circles in the photograph 1, and remove the timing belt for driving roller 3. Remove the C ring and then remove the pulley unit (idler) in the photograph 1. 4. Remove the 4 screws in the squres in the photographs1 and 2. Photograph 1 Timing belt for driving conveyer
Photograph 2
Pulley unit (idler) Roller driving belt
14
5. Remove the encoder sensor and PPS3 cable, and then take out the cabinet 2 by lifting it up as shown in the right photograph. Cabinet 2
Cabinet 1
6. Inside of the cabinet 1 is as shown in the right photograph.
Circuit protector Capacitor
(Refer to the circuit diagram on page 28.)
AC gear motor
Fan motor
SSR
Power relay
Replacing conveyer belt 1. Remove the 4 screws indicated in the photograph 1
Photograph 1
to remove the cabinet 2 and the conveyer unit.
2. Remove the screw in the circle in the photograph 2 to pull out the shaft.
Photograph 2
Remove the stopper. (Do not lose the plastic balls (2 pcs.) by the side of thumb screw and the sliders (2 pcs.) at both sides.) 3. Remove the screws in the squres in the photographs 2 and 3, and then remove the upper cover.
Photograph 3
4. Remove the screws in the circles in the photograph 4, and then remove the pipes. Remove the bearing stopper installing the roller, and then remove the roller. 5. Replace the belt.
After replacing the belt,
Photograph 4
Install the roller and the pipes. Adjust the belt tenstion with the tension in the squres. (A slack should be 1±0.5mm when pulling up the place indicated with a blue arrow by the force of 400g.) 15
Roller
Pipes
Replacing scraper Remove the 4 screws indicated in the right photograph, and then remove the both bracket Rs. (Both the upper bracket R and the lower one are the same.)
Remove the screws indicated in the right photograph, and then replace the scraper. After replacing it, install the scraper so that 7mm
it appears by 7mm from the edge of the bracket.
16
[Adjustments] Adjusting double feed detection unit Parts names
Folding roller 1
Photo sensor
Hole Detection roller (upper)
Lever Eccentric pin
Fulcrum Folding roller 2
Detection roller (lower) Paper
1. Turn the eccentric pin until the gap between the upper and lower detection rollers is at the maximum setting. Insert a sheet of 70kg (approximately) paper between the detectio rollers.
Eccentric pin Paper Supporting point
2. Turn the eccentric pin until it touches the hole, Then fasten it with the screw. Enlarged veiw
○
× 3. Adjustment completes when the lever does not move by running a sheet of paper between the detection rollers and it moves by running 2 sheets of paper.
17
There should be no gap.
Adjusting folding roller Bearing holder
1. Loosen the 2 screws holding the bearing holder of each roller. Slide the folding rollers 1 and 3 along the elongate hole taking the roller 2 as reference so that these rollers are pressed up the roller 2. 2. Adjust the folding roller 4 taking the folding roller 3 adjusted in the step 1 as reference. * Each roller should be symmetrical to the left and right, and there should be no gap between rollers. (Asymmetrical roller pressure causes snaking or wrinkling.)
* After adjustment, a roller should rotate without flat belt and all rollers should drive together. Screw shaft
Adjusting pressure of pressure roller 1. Turn the screw shaft for adjusting pressure until the top edge of the shaft touches the pin top.
Pin
2. Turn the screw shaft clockwise with a handle for 180゜from the contact position in the step 1.
Belleville spring
(symmetrical to the left and right) * Turning the screw shaft clockwise increases the pressure. * Turning the screw shaft counterclockwise
Care should taken for installed direction of belleville spring.
decreases the pressure. Note: Asymmetrical roller pressure causes snaking or uneven pressurizing.
③ Adjusting interlock switc Circuit diagram
①
①
Handle slot, sealer side
②
Safety cover
③
Folding tray 1
④
Folding tray 2
⑤
Handle slot, folder side
⑤ ④
* 2 pcs. of micro switch (5V, 24V) are set at each 5 interlock switches.
②
The machine operates only when all the micro switches are ON. 18
7.HELP Mode ＜ＨＥＬＰ Mode List＞ HELP Mode No.
Description
Remarks
H-00
Rom version display
H-01
Motor check
H-02
Sensor & switch check
H-03
Motor & clutch check
H-04
Not used
H-05
Error & jam counter
H-06
RAM initialization
H-07
Setting double feed detecting timing
H-08
Total counter display
H-09
Not used
H-10
Not used
H-11
Not used
H-12
Selecting language for display
H-13
Not used
H-14
Not used
* Operation Check Operation of single motor, certain continuous operation, and operation of electrical parts can be executed. In this mode, operation is executed by a single motor to be checked. the status or position of related parts and mechanism.
Care should be taken for
Also, care should be taken not to put
your hands or fingers in the moving parts.
WARNING ! Your hands or fingers may get caught in The machinery and injured.
19
Accessing HELP mode 1. Turn the power switch ON while pressing the JOG key and MODE key. 2. A buzzer sounds and the HELP mode is displayed. 3. Select HELP mode no. by pressing the JOG key or MODE key. 4. Press the START key to enter the HELP mode that you selected in the step 3.
If you want to return to
the mode selection display, press the STOP key.
[ＨＥＬＰ Mode Description] 1. H-00： ROM version display: The ROM version of the main PCB unit is displayed. Access the HELP mode H-00, and the press the START key. H-00:
V*.**
2. H-01： Motor check: Operation check of the folding motor and sealer motor. Access the HELP mode H-01, and the press the START key.
The folding motor and sealer motor will
rotate. MOTOR RUN
3. H-02： Motor & clutch check: Operation check of the folding motor and feed clutch. Access the HELP mode H-02, and the press the START key.
The folding motor will rotate.
The feed clutch will be ON while the TEST key is pressed. TEST ->CLUTCH ON
4. H-03： Sensor & switch check: Operation check of the sensors and switches Access the HELP mode H-03, and the press the START key. 0000 0000 0000 ABCD EFGH IJKL A： Paper empty sensor (paper 0, no paper 1) B： Folder encoder (photopassing 0, photointerrupting 1) Ｃ： Sealer encoder sensor (photopassing 0,
photointerrupting 1)
Ｄ：PPS1 (photopassing 0,
photointerrupting 1)
Ｅ： PPS2(photopassing 0,
photointerrupting 1)
Ｆ： Folding handle cover SW (ON 0, OFF 1) Ｇ：PPS3 (photopassing 1, photointerrupting 0) H： Folding plate SW(ON 0, OFF 1) Ｉ： Sealer handle cover SW (ON 0, OFF 1) Ｊ： Double feed detecting sensor (photopassing 0,
photointerrupting 1)
K： Sealer cover SW (ON 0, OFF 1) L： Not used 20
5. H-04： Not used.
6. H-05： Error & jam counter: Checking number of error occurrences Access the HELP mode H-05, and the press the START key. Press the JOG key to check the item. Press the MODE key for 2 seconds to clear the counter. (Each error can be counted up to 9,999.) FEED MISS
****
F.JAM1
****
F.JAM2
****
F.M.LOCK
****
CONV.JAM
****
S.JAM
****
S.M.LOCK
****
DBL JAM
****
7. H-06： RAM initialization Access the HELP mode H-06, and the press the START key. The MODE key and JOG key.
The entire RAM is initialized by pressing
(The machine will return to factory setting.)
MODE + JOG
8.H-07： Setting double feed detecting timing: Chattering time of the double feed detecting sensor is set. Access the HELP mode H-07, and the press the START key. Press the MODE key to select the A to D. Press the JOG key to select 0 or 1. Press the START key to set the setting. Press the STOP key to cancel the setting. (Factory setting: 0011) A:0 B:0 C:1 D:1 0000：8ms、0001：16ms、0010：24ms、0011：32ms、0100：40ms 0101：48ms、0110：56ms、0111：64ms、1000：72ms、1001：80ms 1010：88ms、1011：96ms、1100：104ms、1101：112ms、1110：120ms 1111：128ms
9.H-08： Total counter display Access the HELP mode H-08, and the press the START key.
Total counter will appear on the
display. TOTAL : ******** It can display up to 99999999. (When it exceeds 99999999, it will start with 0 again.)
10. H-09： Not used.
11. H-10： Not used. 21
12. H-11： Not used.
13. H-12： Selecting language for display Access the HELP mode H-12, and the press the START key. A:0 B:0 C:0 D:0 （HELP6 RAM initialization: 0001） 0000
English, 0001 Japanese
14. H-13： Not used.
15. H-14： Not used.
22
8. Error Massage Displays 1. COVER OPEN (without warning beep)
COVER OPEN Status: The safety cover is open. The safety cover is opened during operation Solution: Close the safety cover.
2. NO PAPER (without warning beep)
NO PAPER Status: The START key or TEST key is pressed with no paper on the feed tray. Solution: 1. Load paper. 2. Press the STOP/C key.
3. MISS FEED (with warning beep)
MISS FEED Status: 1. While the paper feed clutch driving signal is lit, the PPS1 cannot detect the paper edge. 2. The PPS1 keeps detecting photointerrupting status for a certain period of time. Solution: 1. Remove jammed paper. 2. Press the STOP/C key.
4. FOLDER JAM 1 (with warning beep)
FOLDER JAM 1 Status: The PPS1 detects the paper, but the PPS2 does not detect it. Solution: 1. Remove jammed paper. 2. Press the STOP/C key.
5. FOLDER JAM 2 (with warning beep)
FOLDER JAM 2 Status: The PPS2 detects the paper and continues detecting. Solution: 1. Remove jammed paper. 2. Press the STOP/C key.
23
6. MOTOR LOCK (with warning beep)
F.MOTOR LOCK
RESET BREAKER
Status: The encoder sensor keeps detecting photointerrupting or photopassing for a certain period of time, and the folding motor does not run. Solution A: 1. Remove jammed paper. 2. Press the STOP/C key. Solution B: Press the breaker in the back of the folding tray 2.
7. CONVEYER JAM (with warning beep)
CONVEYER JAM Status: The PPS2 detects the paper, but the PPS3 does not detect it. Solution: 1. Remove jammed paper. 2. Press the STOP/C key.
8. SEALER JAM (with warning beep)
SEALER JAM Status: 1. The PPS3 keeps detecting the paper. 2. The first paper does not pass through the PPS1, PPS2, and PPS3 in order.
(This happens
When normal operation is executed without removing the paper in the cross conveyer after Folding test.) Solution: 1. Remove jammed paper. 2. Press the STOP/C key.
9. S. MOTOR LOCK (with warning beep)
S.MOTOR LOCK
RESET BREAKER
Status: The encoder sensor keeps detecting photointerrupting or photopassing for a certain period of time, and the sealer motor does not run. Solution A: 1. Remove jammed paper. 2. Press the STOP/C key. Solution B: Press the breaker above the power switch.
10. DOUBLE FEED (with warning beep)
DOUBLE FEED Status: The double feed sensor detects photointerrupting for a certain period of time during operation. Solution: 1. Remove jammed paper. 2. Press the STOP/C key. 24
11. REMOVE PAPER
REMOVE PAPER Status: The START, TEST or JOG key was pressed when any of PPS detects photo interrupting. (This message appears after folding test only when folding test is executed.) Solution A: 1. Remove jammed paper. 2. Press the STOP/C key. Solution B: Open the sealer cover or press the STOP key.
25
9. Electrical parts Connector layout ①Main PCB unit
②Switching power supply PCB unit
③Memory PCB unit
26
Circuit diagram
2005.02 28
