Page 1 2S Trimmer Service Manual Nagel 2S Trimmer...
Page 3: Table Of Contents
6.1.3 Removal Lower Knife ........................82 6.1.4 Placement Lower Knife ........................83 6.1.5 Placement Upper Knife ........................84 6.1.6 Adjustment Upper Knife ........................85 6.1.7 Adjustment Lower Knife ........................86 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 4: Pcb's (Continued)
ESET ALUES MAINTENANCE............................. 134 9.1 P ......................134 REVENTIVE MAINTENANCE TABLE 9.2 S ............................135 CHEMATICS 9.2.1 DTEO-0000-0121-0000......................... 135 9.2.2 DTEO-0000-0142-0000......................... 135 9.2.3 DTEO-0000-0143-0000......................... 135 10. TECHNICAL INFORMATION........................ 136 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 5: Safety
10 meters of the concerning machines. RoHS The 2-Side Trimmer is RoHS compliant. ONLY use RoHS compliant replacement parts ordered from SDD. compliant © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 6: General
STR by using a different Centre Offset (symmetrical or asymmetrical): 33,5mm Waste 18,5mm Waste 3,5mm Waste Centre Offset: 15mm Centre Offset: Centre Offset: -15mm Finished Size: Infeed Size: 260.0mm 297.0mm 33,5mm Waste 3,5mm Waste 18,5mm Waste Fig. 2.1 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 7: Type Of Machine And Tag
The number that is marked on this label (Fig. 2.4) indicates the type (TAG) of the machine. If nothing is marked, the type of machine is a TAG0. Use only the appropriate settings/procedure for the type of machine! Fig. 2.2 Fig. 2.3 Fig. 2.4 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 8: G Etting To Know The Str
All direction are seen from the paper flow direction. Front Right Rear Left Bottom Fig. 2.5 Action Top Cover Booklet Infeed Trim Waste Bin Power switch (inside) User Interface (UI) Booklet Outfeed © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 9: Components Overview Inside
J-Motor4 J-Motor3 Outfeed Infeed J3/P3 PCB5 J5/P5 PCB6 Motor6 Fig. 2.7 = print board J-Motorx Motor conn. Position Switch position Jx/Px = Connector position Sensor position Motorx Motor position © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 10: Components Overview Inside
= Printboard position J-Motorx Motor conn. Position Terminal Rail Jx/Px = Connector position Sensor position Rectifier position = Switch position Motorx Motor position Capacitor postion Trafox = Transformer position Relais position © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 11 Relais position Trimmer/Paper Stop Switch position Capacitor position Transport Belts Motorx Motor position S100 Power switch position Netfilter connector CNT1 Counter position Power Outlet connector Solenoid position Sensor position © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 12 Motor2 Motor7 Motor1 Side Knife Infeed Outfeed Knife Motor8 Side Motor3 Motor4 J-Motor3 J-Motor4 J7/P7 Fig. 2.10 J-Motorx Motor conn. Position Switch position Motorx Motor position Jx/Px Connector position © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 13: Components Overview Interlock Breaker & Safety Block For Knife Beam
Overriding the Interlock circuit is dangerous! This should only be done by a trained Caution!!! Service Engineer when no other solutions are possible! Fig. 2.12 Fig. 2.13 Fig. 2.14 Fig. 2.15 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 14: Components Overview I-Can Plug & Mode Selection Plug
Otherwise communication problems can arise. Fig. 2.16 Fig. 2.17 Attention!!! Make sure the Mode Selection plug [6P13] (Fig. 2.18 & 2.19) is present. Otherwise communication problems can arise. 6P13 Fig. 2.18 Fig. 2.19 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 15: Rollers And Belts
Conveyor Roller 2 Cpl.(A) OGMO-0000-0272-0000 Conveyor Roller 2 Cpl.(A) OGMO-0000-0272-0000 Conveyor Roller 1 Cpl. OGMO-0000-0052-0000 Thickness Measurement System OGMO-0000-0737-0000 Belts Description Article code 3X Belt (Flat) UU20U 1521-6%x30mm ( OMRE-0000-0055-0000 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 16 OGMO-0000-0274-0000 Conveyor Roller 3 Cpl.(B) OGMO-0000-0273-0000 Conveyor Roller 1 Cpl. OGMO-0000-0052-0000 Belts Description Article code 1X Belt (Flat) UU20U 1158-6%x30mm ( OMRE-0000-0054-0000 1X Belt (Flat) UU20U 1002-8%x30mm ( OMRE-0000-0056-0000 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 17 2.2 Getting to know the STR (continued) 2.2.5 Rollers and Belts (continued) Control Board Belts Description Article code 1X Tooth Belt T5 107510 L=1075 ( OMRT-0000-0002-0000 1X Tooth Belt T5 42010 L=420 ( OMRT-0000-0003-0000 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 18: Interface Signals Explanation
Direction Purpose Alternate Interface From previous machine -> next To give the status from the machine Ready / Not ready machine. after the STR to the machine in front. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 19: Global Functionality Description
Go to Bypass mode by continue chapter: Go to Trimming mode by continue chapter: 3.1 Bypass mode 3.2 Trimming mode On the following pages both operating modes are explained in more detailed steps. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 20: B Ypass Mode
III) The infeed sensor (FC3) is inactive. Sensor (FC3) activation should be less than 1 second, after that the STR will give an error STR102. To check that the booklet have transported into the STR. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 21 Motor8 The Side Joggers aligning the booklet. Motor7 VI) When the Side Joggers are reaching the absolute position (adjusted Side Trim size) the Side Joggers will stop. Motor8 Motor7 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 22 IX) The solenoid M1 will be activated and the Paper-stop is going down. The belt propulsion motor (Motor5) starts. The booklet is transported to the output side of the STR. Motor5 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 23 To check if the booklet was transported out of the STR correctly. The belt propulsion motor (Motor5) stops. The booklet is transported out of the STR. Motor5 Contents 3 Global functionality description (continued) © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 24: T Rimming Mode
Sensor (FC3) activation should be less than 1 second, after that the STR will give an error STR102. To check that the booklet have transported into the STR. Booklet is checked on thickness (FC6). © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 25 Motor8 The Side Joggers aligning the booklet. Motor7 VI) When the Side Joggers are reaching the absolute position (adjusted Side Trim size) the Side Joggers will stop. Motor8 Motor7 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 26 ‘Finished Size’. Motor4 Motor3 Knife home switch S10 and S12 are deactivated. The counter (CNT1) adds 1 Trim-cycle to the total. 0001 Contents 3 Global functionality description (continued) © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 27 XII) Solenoid M1 will be activated and the Paper-stop is going down. The belt propulsion motor (Motor5) starts. The booklet is transported to the output side of the STR. Motor5 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 28 STR will give an error STR106. To check if the booklet was transported out of the STR correctly. The belt propulsion motor (Motor5) stops. The booklet is transported out of the STR. Motor5 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 29: Covers
Lift the Front cover upwards to unhook the cover at the lower end. (See Fig. 4.3 & 4.4) Disconnect the Ground wire Remove the Front cover Installation Action Remarks For installation follow the Removal procedure in reversed order. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 30: Rear Cover
Lift Rear cover upwards to unhook the cover at the lower end. (See Fig. 4.7 & 4.8) Disconnect the Ground wire Remove the Rear cover Installation Action Remarks For installation follow the Removal procedure in reversed order. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 31: Upper Infeed Cover
Remove Screws [A] & [B] on both sides of the STR (See Fig. 4.10 & 4.11) Remove the Upper Infeed cover from the machine. (See Fig. 4.9) Installation Action Remarks For installation follow the Removal procedure in reversed order. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 32: Lower Infeed Cover
Remove Screws [C] & [D] on both sides of the STR (See Fig. 4.13 & 4.14) Remove the Lower Infeed cover from the machine. (See Fig. 4.12) Installation Action Remarks For installation follow the Removal procedure in reversed order. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 33: Upper Outfeed Cover
Remove Screws [E] & [F] on both sides of the STR (See Fig. 4.16 & 4.17) Remove the Upper Outfeed cover from the machine. (See Fig. 4.15) Installation Action Remarks For installation follow the Removal procedure in reversed order. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 34: Lower Outfeed Cover
Remove Screws [G] & [H] on both sides of the STR (See Fig. 4.19 & 4.20) Remove the Lower Outfeed cover from the machine. (See Fig. 4.18) Installation Action Remarks For installation follow the Removal procedure in reversed order. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 35: Base Plate Cover
Remove Screws [J] & [K] on the back of Base STR (See Fig. 4.21) Remove Base Plate cover from the machine. (See Fig. 4.22) Installation Action Remarks For installation follow the Removal procedure in reversed order. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 36: User Interface Cover
Remove Screws [L] & [M] on the back of the User Interface (See Fig. 4.23) Remove User Interface cover from the machine. (See Fig. 4.24) Installation Action Remarks For installation follow the Removal procedure in reversed order. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 37: Troubleshooting
Use the ‘▲ / ▼ buttons’ to select the Target that need to be checked and press the ‘Enter’ button. Press the ‘ ’ button to exit the Service Program mode and enter the Operator mode. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 38: Software Version
Use the ‘▲ / ▼ buttons’ to select ‘Software version’ and press the ‘Enter’ button. Check the Software version of the CPU(PCB6), MD6DC(PCB1) and MD6DC(PCB5). Press the ‘ ’ button to exit the Service Program mode and enter the Operator mode. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 39: Fig. 5.7
Press the ‘Start’ button to start the self diagnostic mode and press ‘Stop’ to end the self diagnostic mode. Press the ‘ ’ button to exit the Service Program mode and enter the Operator mode. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 40: Motors
After checking press the ‘OFF’ buttons to change the Status of the Motor back in the ‘normal’ situation. Press the ‘ ’ button to exit the Service Program mode and enter the Operator mode. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 41: Solenoids
After checking press the ‘OFF’ buttons to change the Status of the Solenoid back in the ‘normal’ situation. Press the ‘ ’ button to exit the Service Program mode and enter the Operator mode. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 42: Sensors And Switches
Check the Value : When :0/‘Low’ the sensor is not activated, when :1/‘High’ the sensor is activated. Press the ‘ ’ button to exit the Service Program mode and enter the Operator mode. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 43: Voltmeters
M7 Side Jogger Stacker Unregulated PCB5 23-43V Unregulated 36V (after interlock PCB3, after K1) measured on PCB5. Voltage supplies: M3 Knife 2 M4 Knife 2 M6 Width adjust M8 Side Jogger © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 44: Non Volatile Memory (Nvm)
Use the ‘+ / -‘ buttons to set a NewValue(Dec) and press the ‘OK’ button. Press the ‘ESC’ or ‘ ’ button to exit the Service Program mode and enter the Operator mode. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 45: Dead Cycle
Use the ‘Start’ button to select the start the Dead cycle and the ‘Stop’ button to end the Dead cycle. Press the ‘ESC’ or ‘ ’ button to exit the Service Program mode and enter the Operator mode. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 46: Calibration
Contents 5. Troubleshooting (continued) 5.1 Service program mode (continued) 5.1.9 Calibration Can be used for adjusting the Side Jogger correction. See chapter 8.2.2 NVM Side Jogger correction. Fig. 5.29 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 47: F Ault C Ode D Escriptions
Jogger2 Not Home STR 043 STR M6 Motor6 Home to high STR 045 STR PCB1 No response from MD6DC PCB1 STR 046 STR PCB5 No response from MD6DC PCB5 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 48 STR 103 JAM FC2 Not Covered STR 104 JAM FC2 Not Uncovered STR 105 JAM FC1 Not Covered STR 106 JAM FC1 Not Uncovered STR 107 JAM FC4 or FC7 Trim Waste Bin Full © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 49 Disconnect plug 1P3 from PCB1 and cycle Motor M1. Measure between points 2 and 3. The voltage is approximately 12VDC? Replace PCB1 Replace wire harness Replace wire harness Replace Motor M1 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 50 Motor2 (STR M2) The motor energizes? Go to STR 006 – Motor 2 Open Circuit 1. Make sure that nothing interferes with the mechanical movement. 2. Lubricate where needed. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 51 Check connector 1P3 wires for Short circuit across leads. (Orange5 & Violet8) Is there a Short Circuit? Replace STR-PCB1 Replace wire harness Replace wire harness Replace wire harness Replace wire harness Replace wire harness Replace Counter STR-CNT1 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 52 Disconnect plug 5P3 from PCB5 Check wires for Short Circuit across leads. (Red2 & Black3) Is there a Short Circuit? Replace PCB5 Replace wire harness Replace wire harness Replace motor STR-M3 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 53 Motor4 (STR M4) The motor energizes? Go to STR 012 – Motor 4 Open Circuit 1. Make sure that nothing interferes with the mechanical movement. 2. Lubricate where needed. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 54 Disconnect plug 5P3 from PCB1 and cycle Motor M3. Measure between points 6 and 7. The voltage is approximately 22VDC? Replace PCB5 Replace wire harness Replace wire harness Replace Motor M4 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 55 Disconnect the wires from Motor M5. Run the diagnostics. Fault code STR 016(Open Circuit) is displayed? Disconnect plug 1P2 from PCB1 Check wires for Short Circuit across leads. (Orange4 & Violet11) Is there a Short Circuit? Replace PCB1 Replace wire harness Replace motor STR-M5 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 56 Enter service mode and start Motor6. The motor starts? Go to STR 020 Motor 6 Open Circuit Check for obstructions STR 018 Motor6 Cycle Timeout • Go to STR 020 – Motor6 Open Circuit © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 57 Disconnect plug 5P2 from PCB5 and cycle Motor M6. Measure between points 4 and 11. The voltage is approximately 22VDC? Replace PCB5 Replace wire harness Replace wire harness Replace Motor M6 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 58 Enter service mode and start Motor7. The motor starts? Go to STR 024 Motor 7 Open Circuit Check for obstructions STR 022 Motor7 Cycle Timeout • Go to STR 024 – Motor7 Open Circuit © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 59 Disconnect plug 1P2 from PCB1 and cycle Motor M7. Measure between points 2 and 9. The voltage is approximately 22VDC? Replace PCB1 Replace wire harness Replace wire harness Replace Motor M7 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 60 Enter service mode and start Motor8. The motor starts? Go to STR 028 Motor 8 Open Circuit Check for obstructions STR 026 Motor8 Cycle Timeout • Go to STR 027 – Motor8 Open Circuit © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 61 Disconnect plug 1P2 from PCB1 and cycle Motor M7. Measure between points 2 and 9. The voltage is approximately 22VDC? Replace PCB1 Replace wire harness Replace wire harness Replace Motor M7 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 62 Replace PCB1, reconnect all wires. Run the diagnostics. Fault code STR 029 (Open Circuit) is displayed? No action Replace PCB3 Replace wire harness Replace wire harness Replace wire harness Replace Magnet1 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 63 Disconnect connector J1. Measure between points 5 and 11. The voltage is approximately 22VDC? Disconnect plug 1P2 from PCB1 Measure between point 3 and 10. The voltage is approximately 22VDC? Replace PCB1 Replace wire harness Replace wire harness Belt Stacker Motor1 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 64 Check if Side Jogger isn’t damaged or loosened. Side Jogger is ok? Replace Side Jogger Correct NVM values of Side Jogger Check if S11 is activated using the service menu. S11 is activated? Replace wire harness Retest procedure © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 65 Adjust S1 and calibrate (See Chap. 6.3.4.) Check for obstructions and retest procedure. Check if S1 is activated using the service menu. S1 is activated? Replace wire harness Retest procedure © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 66 Check wiring between PCB1 and PCB5. Are there any loose or broken wires? Check wiring between PCB5 and PCB6. Are there any loose or broken wires? Replace PCB1 Replace wiring harness Replace wiring harness © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 67 Check wiring between PCB1 and PCB5. Are there any loose or broken wires? Check wiring between PCB5 and PCB6. Are there any loose or broken wires? Replace PCB5 Replace wiring harness Replace wiring harness © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 68 Disconnect the connector 1P13. Measure between points 11 and 12. The voltage is approximately 5VDC? Replace PCB1 1. Replace wire harness 2. Replace PCB2 Adjust or replace sensor FC2 (STR-FC2) Check for obstructions and retest procedure. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 69 The voltage is approximately 5VDC? Replace PCB1 1. Replace wire harness 2. Replace PCB2 Adjust or replace sensor FC4 or FC7 (STR-FC4 or FC7) Check for obstructions and retest procedure © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 70 5VDC? Check wires for damage. Are the wires damaged? Replace PCB6 Replace wire harness Adjust or replace sensor FC6 (STR-FC6) Check for obstructions, check adjustment FC6 and retest procedure. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 71 Check if K2 isn’t loose. K2 is loose? Check the wiring for K2. Connectors 3P12 and 3P14 are plugged in? Connect 3P12 and 3P14 Replace wire harness Tighten K2 Replace K2 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 72 1. Replace S9 2. Disconnect the plugs from switch STR-S9. Check wires for Continuity/Short circuit across leads. Is there a short circuit/no continuity? Replace wire harness Replace PCB6 Check mechanics © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 73 1. Replace S12 2. Disconnect the plugs from switch STR-S12. Check wires for Continuity/Short circuit across leads. Is there a short circuit/no continuity? Replace wire harness Replace PCB5 Check mechanics © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 74 2. Disconnect the plugs from switch STR-S19. Check wires for Continuity/Short circuit across leads. Is there a short circuit/no continuity? Replace wire harness Replace PCB1 Check mechanics STR 071 S18 Faulty Not available. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 75 Measure the Violet wire. Is there continuity? Replace wire harness Measure the Black wire. Is there continuity? Replace wire harness Measure the Red wire. Is there continuity? Replace wire harness Replace PCB3 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 76 Check 1P11 wire for damage or Short Circuit across leads. (Red1&Black2) Is there damage or a short Circuit? Disconnect connector 3P5. Measure between pin 1 and pin2. The voltage is approximately 36VDC? Replace PCB3 1. Replace wire harness 2. Replace K1 Replace wire harness Replace PCB1 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 77 2. Replace K1 Replace wire harness Replace wire harness Replace wire harness Replace PCB5 STR 089 36V M6DC PCB5 High • Go to STR 088 – 36V M6DC PCB5 Low © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 78 Clear paper area, by opening the cover and remove the booklet. The Paper path sensor (FC2) is deactivated? Go to STR 052 FC2 Faulty. Make sure that nothing interferes with the paper path and close cover. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 79 The Waste bin sensor lights up when the sensor is blocked and doesn’t light up when the sensor is not blocked? Go to STR 054 FC4 or FC7 Faulty. 1. Make sure that nothing interferes with the waste bin and close the waste bin. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 80: Default / Basic Adjustments
Turn OFF the power switch and disconnect the power to the STR. Undock the STR from other machines. Remove the Front or Rear* Cover. *Depending on knife. Open the Top Cover. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 81: Removal Upper Knife
Remove Screws [E] (6X) with cup spring washers. (See Fig. 6.5) Remove Upper Knife. (See Fig. 6.5) Placement Action Remarks (See Chap. 6.1.5) !!! For placement follow the Placement instructions Upper Knife. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 82: Removal Lower Knife
Turn Screws [M] (3x) Counter Clockwise (CCW) until they passes (See Fig. 6.5) edge [N] Placement Action Remarks (See Chap. 6.1.4) !!! For placement follow the Placement Lower Knife Instructions. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 83: Placement Lower Knife
Turn the Screws [F] a little bit in the Lower Knife so the top of the screws do not stick out and the Lower Knife is hard to move. Remove the Safety Block Continue Adjustment Lower Knife. (See Chap. 6.1.7) © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 84: Placement Upper Knife
Cup Spring Washers. (The Washers can still be turned by the (See Fig. 6.7) fingers) Turn Screws [E] one revolution (360º) clockwise each. (See Fig. 6.7) Continue Adjustment Upper Knife. (See Chap. 6.1.6) © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 85: Adjustment Upper Knife
(See Fig. 6.2) Allen Screws [A] with washers. Turn the Upper Knife down in the lowest position using by turning (See Fig. 6.9) Crank [P] with a 13mm Wrench. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 86: Adjustment Lower Knife
Very slowly lower the Upper Knife by turning Crank [P]. Lower Knife and repeat !!! Check that the Upper Knife does not touch the top of the procedure “Adjustment Upper Lower Knife. Knife” No. 1. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 87 Check the booklet 25 sheets trim quality. !!! Make sure there is no tearing, folding or sticking. Tighten Screws [M] (3x) by fasten Nuts [L] (3x). (See Fig. 6.10) © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 88: Spine Support Knives
Contents 6. Default / basic adjustments (continued) 6.1 Replacing Knives (continued) 6.1.8 Spine Support Knives For replacing the Spine Support Knives see Installation Manual SSK-kit (DBCI-0512-0042-0000). © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 89: Testing / Finishing Adjustments
70 mm (2”3/4) wide at the shorter end. Resharpen at a 25° angle (See Fig. 6.11). The lower knife can be resharpened until it is 38 mm (1”½) wide. Resharpen at a 1° angle (See Fig. 6.11). Fig. 6.11 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 90: Fig
Is the booklet trim waste equal when the offset is set to 0mm? Adjust the NVM value Motor7 and Motor8 Centering Correction according to Chapter 8.2.3 (TAG 1&2) 8.3.3 (TAG 6 and up) The booklet quality is correct. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 91: Trapezium / Diamond Shape
Booklet not Diamond shaped (See corners C) ? Proceed adjusting Trapezium / Diamond Shape on this and following pages. Continue adjusting Side Trim (Finished Size) (See Chapter 6.2.2 Side Trim (Finished Size) Fig. 6.12 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 92: Action
Check is the Paper Stop does not touch the sides of the brackets when the Paper Stop is pushed downwards!!! Continue adjusting Chapter 6.2.1 Trapezium / diamond Shape See next page (continued). © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 93 Only move a full teeth = 0,25mm. If (C) or (D) < 0,5 tooth round down to 0 teeth, If (C) or (D) > 0,5 tooth round up to 1 tooth !!! © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 94 2. Move wheel 2 ‘D’ number of teeth with respect to the marked tooth belt. (See Fig. 6.14) Place the tooth belt back on wheel 2. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 95: Side Trim (Finished Size)
Size displayed on the UI. If the measured Finished Size is the same as UI-Finished Size the adjustment is complete. If not, adjusting the NVM Values by continue chapter: 8.2 Adjusting NVM Values © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 96: Replace Photo Sensors
These are easy to solve by carry out the instructions displayed on the UI and/or using the Fault Code Descriptions (See Chap. 5.2). Always open the Top Cover of the STR before clearing the paper jam. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 97 Disconnect the orange Photo sensor cable. Remove the Photo sensor [HK12PB8] inside the STR. (See Fig. 6.21 – 6.24) Installation Action Remarks For installation follow the Removal procedure in reversed order. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 98 Disconnect the orange Photo sensor cable. Remove the Photo sensor FC4 or FC7 [LK89PD8] inside the Base. (See Fig. 6.25 & 6.26) Installation Action Remarks For installation follow the Removal procedure in reversed order. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 99: Adjusting Photo Sensors
When the photo sensor light is on, there is something seen in his range. When the photo sensor light is off, the range is clear. more sensitive less sensitive Fig. 6.27 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 100 When the Photo sensor lights up, the paper is in his range. After that adjust the Photo sensor one stripe further than it was adjusted in step No. 3. It turns off when the paper is removed. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 101 (See Fig. 6.31) sensor to the maximum. When the Photo sensor lights beam is visible on the Reflection (See Fig. 6.32) sticker, it will be reflected to the Photo sensor. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 102: Replace Switches
Switch off the main power switch and disconnect the power cord. Locate the replacable Switch by using Chap. 2.2.2 Loosen the Bolts and replace the Switch. Installation Action Remarks For installation follow the Removal procedure in reversed order. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 103: Adjusting Switches
Move the Kniveblocks inwards to the Paperstop Unit by turning the Tooth belt 1 on the Control Board (Clockwise = CW) until the distance between the LowerKnives on both side is between 198mm and 199mm. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 104 Check if the distance between the LowerKnives on both side is (See no. 2) between 198mm and 199mm. Otherwise adjust Switch 1 again until it switched between 198mm and 199mm. Check Side Trim (Finished Size) by continuing Chap. 6.22. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 105 Microswitch [Click!] and then tighten the screws [D]. !!! Make sure that the side of the Microswitch (with roller lever) does not stick out the black block (except the roller lever)! © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 106 Adjust the Microswitch (that when the jogger plate is retracted) the (See C) roller lever is hit and switched. !!! The red ridge [C]of the Microswitch is activated [Click!] and approximately ± 2mm pressed! © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 107 Upper knife down and back upwards. !!! The Actuator Plate should switch the Microswitch when the Upper Knife is in the highest position (black stripe is in line). © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 108 (See Fig. 6.36 & 6.33) tolerance by adjusting the bolts [D]!!! (DO NOT adjust the Side Jogger bracket to tight because the Side Jogger Plate should move in and out easily) © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 109 (inside the Side Jogger bracket [D] ) : white S11-3 / S13-2 black S11-1 / S13-1. Remove the ‘old’ Side Jogger and continue Adjusting Side Joggers on the next page. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 110 Use the ‘▲ / ▼’ buttons to select the Motor (M7 or M8) that needs (See Fig. 6.43) to be squared against the Lower Knife, press ‘Enter’ and continue next page. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 111 Place Front or Rear Cover. (See Chap. or 4.2) After adjusting the Side Joggers continue chapter ‘ 8 NVM Values’ 8.2.2 NVM Side Jogger to calibrate the Side Jogger correction NVM values. correction © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 112 Loctite 243. Check again if the Sprocket are in line with each other. (See Fig. 6.47) Repeat this step for the other side of the Knife Block. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 113 The ‘short’ chain at the smallest distance. Hook the links of the chains together with a separate link. (See Fig. 6.55 & 6.56) © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 114 Pay attention that the Chain closure is mounted along the rotation direction (the ‘open-side’ should be rear-facing). Make sure that the Chains are in/between the Chain tensioners. (See Fig. 6.59) © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 115: M Otor And E Ncoder Positions
(See Fig. 6.59) Motor 1, Knife (See Fig. 6.60) Motor 2, Knife (See Fig. 6.60) Motor 7, Side Jogger (See Fig. 6.60) Motor 5, Belt Propulsion (See Fig. 6.60) © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 116: Remove Ui Cover
50Hz’ or ‘Disconnects only BLTXX02 120VAC 60Hz’ depending accessories on the wall outlet voltage. (See Fig. 6.64) Installation Action Remarks For placing back Rear Cover follow the Rear Cover procedure in See Chap. reversed order. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 117 Check which symptom the machine shows Remove the blown out Fuse (Transformer [F14/ F15] or Fuse holder [F12]). Installation Action Remarks For installation follow the Removal procedure in reversed order. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 118: A Djusting T Hickness Detection
By booklet 27 sheets 80gms the Value should be High. (See Fig. 6.70) (See Fig. 6.67 & 6.68) NOTE!: Do not press to hard by adjusting screw A otherwise the Thickness detection is pressed backwards! © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 119: Pcb's
After downloading perform a NVM reset and insert the correct NVM See Chap. values according to the List in the Back Cover. Contents 7 PCB’S (continued) © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 120: Pcb5 Md6Dc
Run the right software application for the type of machine and follow the instructions in the program. After downloading perform an NVM reset and insert the correct See Chap. NVM values according to the List in the Back Cover. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 121: Pcb6 Cpu
Run the right software application for the type of machine and follow the instructions in the program. After downloading perform an NVM reset and insert the correct See Chap. NVM values according to the List in the Back Cover. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 122 7.2.2 Contrast setting (R41) of the LCD. After downloading perform an NVM reset and insert the correct See Chap. NVM values according to the List in the Back Cover. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 123: Led's & Test Points
- Measure between Test Point VCC and Test Point GND/PGND using a voltmeter. The voltage will be shown on the voltmeter. Range 4.9-5.1V. GND / PGND: Ground /Power Ground is the minus when measuring either unregulated 36V (+UNREG) or 5V (VCC). © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 124: Cpu Pcb6 & Pcb7
PCB is used. The current peak will flow through a resistor (PTC, cold resistance 18R) and the start current is limited to 12,7A (230VAC/18R=12,7A). After about 20ms the relay will short circuit the resistor and the machine is ready to use. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 125: Interlock Pcb3
Measure between Test Point +24V and Test Point PGND using a voltmeter. The voltage will be shown on the voltmeter. Range 23-25V. PGND (TP2): Power Ground is the minus when measuring either unregulated 36V (+UNREG) or 24V (+24V). Contents 8. NVM Values © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 126: C Urrent Nvm V Alues
Use the ‘▲ / ▼’ buttons to select the different type of ‘NVM’ Values (See Fig. 8.3) and press the ‘Enter’ button Press the ‘ESC’ or ‘ ’ button to exit the Service Program mode and enter the Operator mode. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 127: A Djusting Nvm V Alues
Motor 8 + : More Compression / Less Trimming Right 1100 1000 1000 - : Less Compression / More Trimming **Recommend to use values < 2000 Fig. 8.9 Fig. 8.10 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 128: Nvm Booklet Width Correction
Change the current NVM No. 1 Motor 6 Home Position in the “new wished NVM No. 1 Motor 6 Home Position. Proceed back to step 1. Proceed to chapter 8.3.2 Fig. 8.11 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 129: Nvm Side Jogger Correction
Enter the Service Program mode [see Chapter 5.1] Use the ‘▲ / ▼ buttons’ to select ‘Calibration’ and press the ‘Enter’ button. Choose the selected ‘Motor7 Compress Correction’ and press the ‘Enter’ button. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 130 For Tag 6 and up: Use the ‘+ / -‘ buttons to set a NewValue(Dec) and press the ‘Save’ button. Proceed back to step 1. Press ’Stop’ to end the Calibration mode and ‘ ’ for exit the Calibration menu. Proceed to chapter 8.3.3 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 131: Nvm Centering Correction
(See Chap. 8.3 Fig. 8.9) More Compression means less Trimming, less Compression means more Trimming The STR is fully adjusted. Write down the adjusted NVM values on the list in the Top Cover. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 132: Nvm Stop If Booklet Too Thick
Use the ‘+ / -‘ buttons to set a NewValue(Dec) 1, 2 or 3 (See options above) and press the ‘OK’ button. Press the ‘ESC’ or ‘ ’ button to exit the Service Program mode and enter the Operator mode. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 133: Reset Nvm Value
Factory Settings 2-Side Trimmer in the Back Cover, and confirm with the ‘Yes’ button. Press the ‘ESC’ or ‘ ’ button to exit the Service Program mode and enter the Operator mode. © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 134: Maintenance
Trim knives Inspect Knives (L+R) Inspect Knife guiding blocks L / I Grease Protection plate knife guidance L / I Grease Knife chains Knife sprockets Side Jogger guidance Grease © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 135: S Chematics
Contents 9. Maintenance (continued) 9.2 Schematics 9.2.1 DTEO-0000-0121-0000 9.2.2 DTEO-0000-0142-0000 9.2.3 DTEO-0000-0143-0000 © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...
Page 136: Technical Information
340 mm must be Booklets Height (Z) 204 mm trimmed back to 320mm or up to 340 mm shorter. 40mm Booklet Staple Clearance from top/bottom (minimal) 70dB Noise Level (max) © Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011...

Nagel 2S Service Manual

Page Intentionally Blank

7. Pcb's (Continued)

Quick Links

Chapters

Related Manuals for Nagel 2S

Summary of Contents for Nagel 2S

Table of Contents