Horizon Fitness PF-P3100 Manual
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I Introduction
This service manual is for the following product.
Paper Folder PF-P3100
Prior consent
This service manual is intended for use when repairing and maintaining this
machine to keep it in top working condition. In order for you to safely perform
repair and maintenance work on this machine, please make sure that you fully
read and understand all of the notes related to safety that are written through-
out this service manual.
-
Horizon International, INC. cannot accept responsibility for any loss, damage, or
injury as a result of unauthorized modification, misuse, or use outside the
machine's specifications, or any unsuitable or inadequate maintenance performed
by you or by authorized service personnel.
-
Horizon International, INC. is continuously working to improve the design and
performance of all of its products. Consequently, the contents of this service
manual may be changed at any time in the future without prior notice.
Furthermore, Horizon International, INC. bears no additional liability for any added
contents.
-
All rights with regards to copyrights are reserved. The copying or distribution of
any part or whole of this manual is strictly prohibited unless prior written
permission is obtained directly from Horizon International, INC.
Caution when undertaking service operations
-
When replacing parts or performing other such maintenance operations, switch
the power supply Off before starting unless it is necessary to keep the power on.
Also, remove the power cable from the socket before starting for additional safety.
-
When removing covers, be extremely cautious of rotating objects such as belts
and pulleys, and of electrical wiring etc.
-
Always perform operations alone. This manual is written on the assumption that
operations will be performed by one person.
-
Make sure that other people do not touch the machine during operation.
-
When turning the power back on, wait for approximately 10 seconds after turning
the power Off before switching it On again.
-
When replacing parts, use the parts shown in the parts book unless commercially
available parts with exactly the same functions and performance can be obtained.
Safety precautions
-
In order to perform repair or maintenance work safely on this machine, thoroughly
read all of the warnings and cautions related to safety that are written in this
service manual BEFORE commencing any operation. Failing to heed the safety
precautions in this manual may lead to accidents resulting in injury or death.
-
The maintenance procedures and safety precautions described in this service
manual are only effective if the repair/maintenance procedures specified for this
machine are followed.
-
Precautions that if not followed correctly may lead to accidents resulting in injury
or death are indicated by this
-
Precautions that if not followed correctly may lead to accidents resulting in
machine damage or malfunctions are indicated by this
-
It is impossible for Horizon International, INC. to prevent all possible dangers
related to this product and its use. Therefore, the precautions shown in this service
manual and warning labels displayed on the product do not completely warn
against all possible dangers.
-
Some of the diagrams in this service manual are drawn with covers removed to
describe the details or internal sections of the machine.
Edited and Published by Horizon International, INC.
070608/PFP3100/00E/TM/HI,MT
I
WARNING
heading.
CAUTION
US503013-00
heading.

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Table of Contents
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Summary of Contents for Horizon Fitness PF-P3100

  • Page 1 This service manual is for the following product. • Safety precautions Paper Folder PF-P3100 In order to perform repair or maintenance work safely on this machine, thoroughly read all of the warnings and cautions related to safety that are written in this service manual BEFORE commencing any operation.
  • Page 2 II Symbols used in this manual 1. Wiring color character code 3. Circuit configuration identification characters and symbols Single color wire color Compound line symbol = Alternating current = Micro-switch BRN = Brown = Brown = Power system Cabtire = Brake MOD = Module connector RED = Red = Red...
  • Page 3 III Cautions when handling the print board and ROM Even an small amount of static electricity that it cannot be felt by people will damage the board or ROM. Exercise caution on the following points when handling the board or ROM. Do not put Board and ROM on the Keep Board in a Acrylic...
  • Page 4: Table Of Contents

    Table of Contents 3-3 Tray Gate Position Adjustment ...........3-4 3-4 Belt Tension Adjustment .............3-5 3-5 Delivery Belt Replacement..........3-6 I Introduction ................I 3-6 Micro-switch Adjustment .............3-7 II Symbols used in this manual..........II III Cautions when handling the print board and ROM..III 4 Mechanical Troubleshooting......
  • Page 5: Installation And Mechanism

    1 Installation and Mechanism 1-1....Installation ................1-2....Main Cover Removal ............1-3....Buckle Chute Removal ............1-4....Mechanism of Folding ............1-5....Feed Table................1-6....Table Up/Down Mechanism..........1-7....Drive Section................ 1-8....Feed Roller Section.............. 1-9....Double Feed Stop Section............ 1-10 1-10.....
  • Page 6: Installation

    1 - 1 Installation 1 Installation and Mechanism 1 - 1 Installation Caution Delivery Roller - Do not install the PF-P3100 on an Assembly unstable or tilted floor. Otherwise, the folder may fall over or the machine frame may be distorted, and this could affect the machine performance.
  • Page 7: Main Cover Removal

    1 Installation and Mechanism 1 - 2 Main Cover Removal Remove the cover F. Control Panel - Remove three lock screws. - Loosen two lock screws of the control panel. - Lift the control panel, and disengage the Cover R control panel from the cover F.
  • Page 8: Buckle Chute Removal

    1 - 3 Buckle Chute Removal 1 Installation and Mechanism 1 - 3 Buckle Chute Removal Frame F Pull out the buckle chute. - Pull out the buckle chute to the arrow direction Stopper Bracket slowly until it stops. (Fig. 1) Frame R Remove the stopper bracket.
  • Page 9: Mechanism Of Folding

    1 Installation and Mechanism 1 - 4 Mechanism of Folding Sheets are fed. Feed Roller Sheets - The feed roller rotates and feeds sheet one by one Feed Roller to the buckle chute. (Fig. 1) Fold Roller The sheet hits the stopper. - The sheet hits the stopper on the 1st buckle chute Double Feed Stop Plate Bending Part...
  • Page 10: Feed Table

    1 - 5 Feed Table 1 Installation and Mechanism 1 - 5 Feed Table Sheet Guide Feed Table Sheet Actuator The sheet guides can be Support Table adjusted on this pivot. Slide Spring Slide Spring Slide Spring Guide Shaft Slide Block This rod is eccentric.
  • Page 11: Table Up/Down Mechanism

    1 Installation and Mechanism 1 - 6 Table Up/Down Mechanism Section A Section A Section A Feed Roller Section A Section A Section A Feed Table Pressure Adjusting Lever Feed Roller Feed Table (Normal) (Normal) (Normal) Fulcrum Shaft Feed Table (Strong) (Strong) (Strong)
  • Page 12: Drive Section

    1 - 7 Drive Section 1 Installation and Mechanism 1 - 7 Drive Section Feed Drive Belt Feed Roller Fold Roller Clutch Solenoid Delivery Section Delivery Drive Belt Drive Timing Belt Delivery Belt 503013 1_7_1A M10 Main Motor M10 Main Motor Conveyor Pulley (DC brushless motor) (DC brushless motor)
  • Page 13: Feed Roller Section

    1 Installation and Mechanism 1 - 8 Feed Roller Section Clutch Spring Clutch Bushing Fixed Bearing Clutch Unit Feed Roller Shaft Clutch Stopper Clutch Lever Feed Roller Clutch Pulley Feed Table Fixed Bearing Free Bearing Clutch Solenoid Feed Roller Insert the feed roller shaft. The feed roller rotates to the Double Feed Stop Plate Clutch Lever...
  • Page 14: Double Feed Stop Section

    1-10 1 - 9 Double Feed Stop Section 1 Installation and Mechanism 1 - 9 Double Feed Stop Section Feed Roller Feed Roller Feed Table Plate Pressure Spring Plate Bracket Double Feed Stop Plate Double Feed Stop Plate Plate Stand Lever Plate Pressure Adjusting Plate Feed Roller Sheet...
  • Page 15: Fold Roller Section

    1 Installation and Mechanism 1 - 10 Fold Roller Section Press the fold driven rollers. Fold Roller Spring Feed Roller Roller Pressure Link Transport Rubber Roller Feed Roller Solenoid O Solenoid ON = When the tray gate When the tray gate is at right. is at right.
  • Page 16: Tray Gate Section

    1-12 1 - 11 Tray Gate Section 1 Installation and Mechanism 1 - 11 Tray Gate Section Tray Gate Gate Fulcrum Shaft Tray Gate Section Side Plate Gate Solenoid (front) Gate Bracket Gate Lever (front) The stop position of the tray gate is where the gate hits When Solenoid ON: When Solenoid ON:...
  • Page 17: Delivery Section

    1 Installation and Mechanism 1 - 12 Delivery Section Main Motor Delivery Belts Conveyor Pulley Delivery Belt Adjust the belt tension by fixing position of the Delivery Tray shaft. Tension Adjustment Tension Adjustment of the Delivery Belt of the Delivery Belt Main Motor Conveyor Pulley 503013...
  • Page 18: Buckle Chute Section

    1-14 1 - 13 Buckle Chute Section 1 Installation and Mechanism 1 - 13 Buckle Chute Section 1st Buckle 1st Buckle Section A Section A Section A Proximity Sensor: B21 Buckle Chute 1st Buckle 1st Buckle Section Lock Screws Lock Screws Lock Screws Chute Stopper Chute Stopper...
  • Page 19: Service Mode And Error Code

    2 Service Mode and Error Code 2-1....Functions of Service Mode ..........2-2....Error Code Chart..............Service Mode and Error Code...
  • Page 20: Functions Of Service Mode

    2 - 1 Functions of Service Mode 2 Service Mode and Error Code 2 - 1 Functions of Service Mode The service mode is the functions listed in the chart to Service Mode How to Enter What You Can Do in This Mode the right can be performed by pressing the power switch and the other buttons together.
  • Page 21: Error Code Chart

    2 Service Mode and Error Code 2 - 2 Error Code Chart Error Cause and Solutions Code [Cause] The fold section cover opens while the motor rotates. (The S10 fold section cover switch turns Off.) [Solution] Close the fold section cover. If the same error still occurs, check wiring/connection between S10 and QPM-243. If the S10 fold section cover switch is On, LED L27 on QPM-243 turns off.
  • Page 22 2 Service Mode and Error Code 2 - 2 Error Code Chart [Cause] Memory reading error: EPROM information can not be read when turning on the power switch. [Solution] Reset the memory using the “Memory Reading Error Reset Mode” in the service function, and operates the folder with the default setting. If the same error still occurs, replace the QPM-243 control board.
  • Page 23: Adjusting And Checking Procedures

    3 Adjusting and Checking Procedures 3-1....Buckle Chute Stopper Angle Adjustment ......3-2....Feed Clutch Unit Adjustment ..........3-3....Tray Gate Position Adjustment ..........3-4....Belt Tension Adjustment ............3-5....Delivery Belt Replacement ..........3-6....Micro-switch Adjustment ............Adjusting and Checking Procedures...
  • Page 24: Buckle Chute Stopper Angle Adjustment

    3 - 1 Buckle Chute Stopper Angle Adjustment 3 Adjusting and Checking Procedures 3 - 1 Buckle Chute Stopper Angle Adjustment 2nd buckle adjustment 2nd buckle adjustment Square window for 2nd stopper Pull out the buckle chute to the arrow direction adjustment slowly until it stops.
  • Page 25: Feed Clutch Unit Adjustment

    3 Adjusting and Checking Procedures 3 - 2 Feed Clutch Unit Adjustment - The feed clutch activates when start and stop feeding the sheet, and Short fold and Accordion Clutch Housing Clutch Bush fold, which the sheet enters into the first buckle Fixed Bearing Fixed chute deeply, are selected.
  • Page 26: Tray Gate Position Adjustment

    3 - 3 Tray Gate Position Adjustment 3 Adjusting and Checking Procedures 3 - 3 Tray Gate Position Adjustment Depending on the position of the tray gate, sheets are delivered, or folded again. The stop position of the tray gate is where the gate hits inside the 14 hole on the side plate.
  • Page 27: Belt Tension Adjustment

    3 Adjusting and Checking Procedures 3 - 4 Belt Tension Adjustment Drive Timing Belt Tension Feed Drive Belt Tension Delivery Belt Tension The tension of the drive timing belt is The tension of the feed drive belt is adjusted by The delivery belts are stretch, therefore, the belt adjusted by the mounting position of the the attaching position of the tension roller.
  • Page 28: Delivery Belt Replacement

    3 - 5 Delivery Belt Replacement 3 Adjusting and Checking Procedures 3 - 5 Delivery Belt Replacement If the delivery belt slips, set the delivery roller shaft at Set Screws for exit side of the slot on the belt bottom plate. Delivery Drive Belt Delivery Drive Belt Delivery Drive Belt...
  • Page 29: Micro-Switch Adjustment

    3 Adjusting and Checking Procedures 3 - 6 Micro-switch Adjustment This section indicates the standard position for the attachment of the three micro-switches used in this machine. : Fold Section Cover Switch : Fold Section Cover Switch S10: Fold Section Cover Switch - ON: When the fold section cover is closed.
  • Page 30 3 Adjusting and Checking Procedures This page is intentionally left blank.
  • Page 31: Mechanical Troubleshooting

    4 Mechanical Troubleshooting 4-1 ....Machine Is Not Powered On..........4-2 ....M10 Main Motor Does Not Rotate ........4-3 ....Tray Gate Malfunctions ............4-4 ....Y01 Clutch Solenoid Does Not Activate ........ 4-5 ....Buckle Chute Proximity Sensor Error........4-6 ....
  • Page 32: Machine Is Not Powered On

    4 - 1 Machine Is Not Powered On 4 Mechanical Troubleshooting 4 - 1 Machine Is Not Powered On Tester The power cable is unplugged from the outlet. Switching The power cable is Fuse on the QPM-243 control Power Supply 100-240V unplugged from the inlet.
  • Page 33: M10 Main Motor Does Not Rotate

    4 Mechanical Troubleshooting 4 - 2 M10 Main Motor Does Not Rotate Interlock is activated Interlock is activated M10 : Main Motor Does Not Rotate M10 : Main Motor Does Not Rotate A10 : Motor driver alarms A10 : Motor driver alarms Interlock Circuit 24 VDC Circuit 24 VDC Circuit...
  • Page 34: Tray Gate Malfunctions

    4 - 3 Tray Gate Malfunctions 4 Mechanical Troubleshooting 4 - 3 Tray Gate Malfunctions - Tray gate closes (= Solenoid Y02 and Y03 turn On) only while the single folding operation. To perform Do solenoids Y02 and Y03 function correctly? Does the tray gate mechanism malfunction? the single folding, the tray gate comes close to the third roller and the folded sheet is delivered to the...
  • Page 35: Y01 Clutch Solenoid Does Not Activate

    4 Mechanical Troubleshooting 4 - 4 Y01 Clutch Solenoid Does Not Activate - When Y01 clutch solenoid is On, Does the feed clutch mechanism malfunction? Does the solenoid Y01 malfunction? the feed roller rotates continuously to feed sheets. When Y01 is Off, the clutch lever stops the clutch stopper rotation, and the feed roller stops.
  • Page 36: Buckle Chute Proximity Sensor Error

    4 - 5 Buckle Chute Proximity Sensor Error 4 Mechanical Troubleshooting 4 - 5 Buckle Chute Proximity Sensor Error - The proximity sensor inside the buckle chute detects Is a piece of paper left in the buckle chute? Does the sensor detecting area get dirty? a sheet and counts the number of feeding.
  • Page 37: Delivery Belt Does Not Move

    4 Mechanical Troubleshooting 4 - 6 Delivery Belt Does Not Move Is the tension of delivery belt loosened? Does the delivery belt drive mechanism malfunction? Delivery Belts Delivery Roller Drive Shaft Delivery Pulley Delivery Belts Delivery Roller Shaft Belt Bottom Plate Tighten the Main Motor screw at the...
  • Page 38 4 Mechanical Troubleshooting This page is intentionally left blank.
  • Page 39: Folding Quality Troubleshooting

    5 Folding Quality Troubleshooting 5-1....Sheets Are Wrinkled ............5-2....Corner of the Sheets Are Folded (Dog Ear)......5-3....Uneven Folding ..............5-4....Fold Skewing ............... 5-5....Delivered Sheets Are Not Neatly Stacked ......5-6....Sheet Jams at the Tray Gate ..........Folding Quality Troubleshooting...
  • Page 40: Sheets Are Wrinkled

    5 - 1 Sheets Are Wrinkled 5 Folding Quality Troubleshooting 5 - 1 Sheets Are Wrinkled Is the buckle chute unit installed incorrectly? Is the tray gate deformed? Positioning Shaft Buckle Chute 503013 5_1_1A Third Fold Roller Tray Gate At Center Correct Incorrect Are the sheets curled or concaved?
  • Page 41: Corner Of The Sheets Are Folded (Dog Ear)

    5 Folding Quality Troubleshooting 5 - 2 Corner of the Sheets Are Folded (Dog Ear) Is the tray gate deformed? 503013 5_2_1A Tray Gate Third Fold Roller At Center Are the jammed sheets left on the sheet path? Incorrect Correct Tray Gate 503013 5_2_1C...
  • Page 42: Uneven Folding

    5 - 3 Uneven Folding 5 Folding Quality Troubleshooting 5 - 3 Uneven Folding Is the jammed sheet left in the buckle chute? Does stopper drive mechanism malfunction? - If a chip of sheet is left in the buckle chute while The sheet edges do not removing a jammed sheet, the folded sheets do not align even though correct...
  • Page 43: Fold Skewing

    5 Folding Quality Troubleshooting 5 - 4 Fold Skewing Is the roller pressure (spring force) not even Is the stopper tilted? at front and rear? 503013 5_4_1A Clamp Handle Sheet Fold Roller Spring Are sheet guides not at right angle against the front stop or not parallel each other? Roller Link Sheet Guide...
  • Page 44: Delivered Sheets Are Not Neatly Stacked

    5 - 5 Delivered Sheets Are Not Neatly Stacked 5 Folding Quality Troubleshooting 5 - 5 Delivered Sheets Are Not Neatly Stacked Does the delivery belt slip? Are antistatic tapes attatched correctly? Delivery Belts Delivery Belts 503013 5_5_1A Does the folded sheet stick each other Delivery because of static? Section Cover...
  • Page 45: Sheet Jams At The Tray Gate

    5 Folding Quality Troubleshooting 5 - 6 Sheet Jams at the Tray Gate Does tray gate mechanism malfunction? Is the tray gate deformed? 503013 5_6_1A Y02/Y03 Y02/Y03 Third Fold Roller Tray Gate Plunger At Center Correct Incorrect Lever Bracket Tray Gate Gate Holder Tray Gate 503013...
  • Page 46 5 Folding Quality Troubleshooting This page is intentionally left blank.
  • Page 47: Electrical Circuit

    6 Electrical Circuit 6-1....Electrical Parts Location and Description......6-2....Power Circuit Wiring Diagram and Interlock Circuit ....6-3....QPM-243 Control P.C.B............6-4....QPW-767/QPW-768 Buckle Chute LED P.C.B..... 6-5....Firmware Update..............6-10 Electrical Circuit...
  • Page 48: Electrical Parts Location And Description

    6 - 1 - 1 Electrical Parts Location (1/3) 6 Electrical Circuit 6 - 1 Electrical Parts Location and Description Electrical Parts Location (1/3) 6 - 1 - Connector Code Name Destination Main Motor DC 50W 6-3-2 Feed Solenoid 24 VDC 6-3-2 Gate Solenoid (front) 24 VDC...
  • Page 49 6 Electrical Circuit 6 - 1 Electrical Parts Location and Description Electrical Parts Location (2/3) 6 - 1 - Connector Code Name V,A,W Destination DC Brushless Motor Driver 24 VDC 6-3-2 Buckle Chute Interlock Relay 24 VDC 6-2-1 Section Switching Power Supply 5, 24 VDC 6-2-1 6-2-1...
  • Page 50 6 - 1 - 1 Electrical Parts Location (3/3) 6 Electrical Circuit 6 - 1 Electrical Parts Location and Description Electrical Parts Location (3/3) 6 - 1 - Connector Code Name Destination Main Motor Power Relay Connector 6-3-2 Main Motor Signal Relay Connector 6-3-2 Fold Section Cover Switch Relay 6-3-2...
  • Page 51: Power Circuit Wiring Diagram And Interlock Circuit

    6 Electrical Circuit 6 - 2 Power Circuit Wiring Diagram and Interlock Circuit Interlock Circuit Wiring Diagram Gate Solenoid (front) CON2 Feed Table SIG S13[L19] CON8 Sheet Detection Switch CON3 Single Phase SIG S12[L20] Feed Bar Switch 100 - 240 VAC Power Supply Feed Solenoid CON1...
  • Page 52: Qpm-243 Control P.c.b

    6 - 3 - 1 LED and DSW on QPM-243 6 Electrical Circuit 6 - 3 QPM-243 Control P.C.B. LED and DSW on QPM-243 6 - 3 - Lighting Condition Download mode is operated. (NMI interruption) 5 VDC is generated on P.C.B. 24 VDC is generated on P.C.B.
  • Page 53 6 Electrical Circuit 6 - 3 QPM-243 Control P.C.B. QPM-243 Connector Connection Diagram 6 - 3 - CON6 CON1 Fold Section Cover Switch SIG S10[L27] Switching CON2 Power Supply Power SIG S13[L19] Feed Table Switch Sheet Detection Switch CON3 SIG S12[L20] Feed Bar Switch Circuit Protector XY02...
  • Page 54: Qpw-767/Qpw-768 Buckle Chute Led P.c.b

    6 - 4 - 1 LED and Connector Layout on QPW-767/(mm) 6 Electrical Circuit 6 - 4 QPW-767/QPW-768 Buckle Chute LED P.C.B. LED and Connector Layout on QPW-767/(mm) 6 - 4 - CON1 Single Fold, Cross Fold Short Fold 1st Buckle Chute Letter Fold Indicator Indicator...
  • Page 55 6 Electrical Circuit 6 - 4 QPW-767/QPW-768 Buckle Chute LED P.C.B. LED and Connector Layout on QPW-768/(inch) 6 - 4 - CON1 Single Fold,Cross Fold Short Fold 1st Buckle Chute 1st Buckle Chute Letter Fold Indicator Indicator Accordion Fold Gate Fold Cross Fold,Short Fold Gate Fold 2nd Buckle Chute...
  • Page 56: Firmwae Update

    Remove the cover F (front). - Find the serial connector and the dip switch. (Fig.1) Control program of PF-P3100 can be updated by transfer- ring the new firmware data from your PC. Set the SW 1 on DSW 1.

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