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Infinity Solutions 5K Service Manual

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Summary of Contents for Infinity Solutions 5K

  • Page 1 Service Manual...

  • Page 3: Table Of Contents

    Table of Contents Service Manual Notes ............................iii Tools Needed ..................................v Parts: ....................................v Technical Help ................................... v Additional Notes ................................. v 1. Machine Overview..…………………………………………………………………………………………………6-7 1.1. Covers………………………………………………………………….………………………………………………………..8 2. Drive Train………………………………………………………….. ………………………………………………..9 2.1. Conveyor Drive Pulley & O-Ring…………………………………………….……………………………………………….9 2.2. Drive Motor: Belt, Pulleys, and Clutch ........................10 2.3 Double Sided Timing Belt and Drive Pulleys ......................

  • Page 5: Service Manual Notes

    The majority of service operations are covered in this manual. However if you are unable to resolve a problem please contact technical support at Infinity Solutions Manufacturing. Phone: (207) 899-1714 Additional Notes This manual is for use with the Infinity Solutions 5K .

  • Page 6: Machine Overview

    1. Machine Overview • Read the operators manual to become familiar with the machine operation. Feed Gauge Cover Paper Guide Electrical Side Cover Feed Table Upper Fold Plate Drive Train Access Door Conveyor Nip Wheels Motor Side Cover Conveyor Figure 1: A...
  • Page 7 Control Panel IEC Assembly, Fig 2 Catch Tray Lower Fold Plate Figure 1: B Power Cord Plug Power Switch / Breaker Figure 2: Power Connection and Switch...

  • Page 8: Covers

    1.1. Covers a) Removal 1. Remove the cover screws (4x). 2. Slide the cover off the machine. b) Installation 1. Installation is the reverse of removal. Cover Cover Screw (4x) Figure 3: Covers...

  • Page 9: Drive Train

    2. Drive Train Roll Gear Feed Drive Belt Feed Drive Pulley Door Switch Double Sided Belt Feed Pinion Pulley Conveyor Pulley Motor Belt 28-0832-00 Motor Pulley and Clutch Figure 4; Drive Train Note: If motor belt is marked 5M450 15, then see addendum 2.1.

  • Page 10: Drive Motor: Belt, Pulleys, And Clutch

    Note: For conveyor pulley and O-ring part #’s see the Appendix. If existing pulley does not have shown hub, then the clear o-ring must be used. Otherwise, the black one is needed. 2.2. Drive Motor: Belt, Pulleys, and Clutch a) Removal •...
  • Page 11 2. With the drive train completely assembled and all protective guards in place plug in the machine and power it 3. Test the adjustment by running a 1 2/3 folded form (See Figure 7) through the back of the machine while it runs at full speed (See Figure 8).

  • Page 12: Double Sided Timing Belt And Drive Pulleys

    2.3. Double Sided Timing Belt and Drive Pulleys Figure 10: Drive Train Exploded View a) Removal • Disconnect the power cord from the machine. 1. Remove the conveyor pulley, motor belt and the gears. (See Section 2.2) 2. Remove the double sided belt. a) Loosen the idler tension bracket and slide the bracket and pulley down to release tension on the belt.

  • Page 13: Feed System

    c) Adjustments 1. With the idler bracket loose, slide the idler wheel and bracket up until the belt is tight. Tension the belt so that the belt and gears move freely with minimal resistance. If the belt is too loose excess noise and premature belt failure can occur.

  • Page 14: Feed Drive Belts

    3.2. Feed Drive Belts a) Removal • Disconnect the power cord from the machine 1. Remove the E-clips from the drive shaft (4x). (See Figure 11) 2. Remove shaft support screws from the side frames. (See Figure 12) 3. Slide the drive shaft through the drive train side frame. 4.

  • Page 15: Feed Gauge Assembly

    4. Feed Gauge Assembly Figure 12: Feed Gauge Assembly d) Removal Adjustment Screw • Disconnect the power cord from the machine. 1. Remove the feed gauge cover. 2. Remove both side covers. 3. Remove the x-tie screws from both side frames. (See Figure 22) 4.
  • Page 16 2. Adjust the feed gauge. f) Adjustment • Disconnect the power cord from the machine. 1. Remove feed gauge cover 2. Place 1 form on the feed table and hand feed the form into the machine by moving the feed belt with your hand.

  • Page 17: Nip Wheel

    5. Nip Wheel NOTE: Static Brush Part #55-0388-00 not shown Figure 15: Nip Wheel g) Removal • Disconnect the power cord from the machine. 1. Remove upper fold plate. 2. Remove 3 Felt Holder thumb screws and remove felt holder assembly 3.

  • Page 18: Conveyor

    Roll Wheel Folded Form Figure 16: Nip Wheel Adjustment NIP WHEELS MAY NOT BE WHITE 6. Conveyor Figure 17: Extended Conveyor...

  • Page 19: Extended Conveyor Belts

    6.1 Extended Conveyor Belts Note: Only the 7K Plus is equipped with the extended conveyor, the 5K is equipped with the standard conveyor which does not contain the additional conveyor table and belts. (This may be purchased as an option) j) Removal •...

  • Page 20: Wiper

    7. Wiper ITEM PartNo DESCRIPTION QTY. 70-0220-00 Felt Holder 70-0221-00 Wiper Felt Strip 84-0164-00 Black #10-32 Thumb Screw UNLESS OTHERWISE SPECIFIED Bri-Lin Corporation ALL DIMENSIONS ARE IN INCHES 16 Amarosa Drive TOLERANCES: ANGLES Rochester, NH 03868 1 PLACE DECIMALS DRAWING TITLE 2 PLACE DECIMALS .010 WIPER ASSEMBLY...

  • Page 21: Rolls

    8. Rolls Note: If roll configuration is different than shown, see addendum Figure 20: Rolls (1) Removal • Disconnect the power cord from the machine. 1. Remove the drive train components. (See Section: 2, page 9) 2. Remove the fold trays, simply lift up trays and slide out of chassis. 3.

  • Page 22: Drive Motor

    11. Slide the drive train side frame off of the rolls and remove. 12. Inspect the rolls for wear and replace any damaged or worn components. a) Clean rolls by wiping down with a household cleaner such as OOPS or the equivalent. (2) Installation 1.
  • Page 23 9. Electrical Figure 23: Electrical Components a) Drive Motor Part #30-0124-00 (1) Removal • Disconnect the power cord from the machine 1. Remove both the side covers. 2. Remove the rear motor guard. a) Unscrew the power switch bracket from the electrical side frame. b) Unscrew and remove the rear motor guard.

  • Page 24: Control Panel

    Control Panel See Figure 22 (1) Removal • Disconnect the power cord from the machine. 1. Remove the electrical side cover. 2. Disconnect wiring of speed pot from drive board. 3. Remove 2 screws that attach Control Panel. 4. Lift the Control Panel straight up, separating it from the Processor Board 5.

  • Page 25: E.10A Iec Bracket Assembly

    e) 10A IEC Bracket Assembly (1) Removal • Disconnect the power cord from the machine. 1. Remove the electrical side cover. 2. Disconnect electrical connections from assembly 3. Remove mounting screws and remove unit. 4. Replace failed components as required (2) Installation Reassemble in reverse order as above (see schematic for wiring)

  • Page 26: Iec Outlet Assembly

    f) IEC Outlet Assembly (1) Replacement • Disconnect the power cord from the machine. 1. Remove the electrical side cover. 2. Disconnect electrical connections from assembly 3. Remove mounting screws and remove unit 4. Replace failed components as required (2) Installation Reassemble in reverse order as above (see schematic for wiring)

  • Page 27: Fold Plate Switch

    FOLD PLATE SWITCH, DPDT Part #39-0581-00 Fold Plate Switch (1) Replacement • Disconnect the power cord from the machine. 1. Remove rear fold plate. 2. Remove side covers to access rear motor cover screws 3. Remove rear motor cover screws and rear motor cover 4.

  • Page 28: Door Switch Assembly

    Door Switch Assembly (1) Replacement • Disconnect the power cord from the machine. 1. Remove side door 2. Disconnect electrical connections from door switch 3. Remove mounting screws and remove unit 4. Replace failed component as required (2) Installation Reassemble in reverse order as above (see schematic for wiring)

  • Page 29: Nip Wheel Assembly With Sensors

    i) NIP Wheel Assembly with Sensor (1) Replacement • Disconnect the power cord from the machine. 1. Remove upper fold plate. 4. Remove 3 Felt Holder thumb screws and remove felt holder assembly 5. While holding NIP WHEEL Assembly, remove 2 screws holding Sensor Mount Bracket and swing assembly down onto exit conveyor.

  • Page 30: Schematic

    j. Schematic...

  • Page 31: Troubleshooting

    10. Troubleshooting 11.1Machine Will Not Power On 1. Check that the power switch / breaker is in the “on” position. (when in the “on” position it will be lit up red) 2. Check that the power cord is properly connected to the machine. 3.
  • Page 32 2. If the sensor is blocked, increase the starting speed of the machine before pressing RUN. (This may be necessary on machines that are running 14” EZ or Return Envelopes.) Also check that NIP Wheel assembly is properly adjusted. 3. If the machine powered off while running check the power switch / breaker. a) If the machine repeatedly shuts off, wait a few minutes and test again.
  • Page 33 11.5 Improper Functioning of the Machine 11.5.1 Misaligned Folds If your forms are running through the machine OK but they’re folding a little bit crooked or are not folding right on the perforation, you need to adjust the fold plate settings. The location of perforations on forms generally fluctuates by about 1/16”...
  • Page 34 b) If no visual problems, remove the motor drive belt. (a) Replace drive train cover and power machine on and run the motor. If the noise is still present replace the motor. (b) If the noise if no longer present the problem has been isolated to the drive train system. Check drive train components again, check rolls, conveyor system for damaged components or foreign object.
  • Page 35 11.6.2 Fold Plate Switch Test the continuity, if the continuity is not correct, replace the switch. This is a double pole double throw switch with N/C, N/O, and Common identified on the switch. N/C SWITCH 1 N/O SWITCH 2 COMMON SW1 N/C SWITCH 2 COMMON SW2 N/O SWITCH 2...

  • Page 36: Appendix

    11. Appendix Side Frame Assembly Drawings...
  • Page 37 SHEET 2 OF 2 ITEM PartNo DESCRIPTION QTY. 70-0210-00 Lower Fold Plate 70-0211-00 Lower Fold Plate Bottom 70-0212-00 Fold Plate Paper Stop 70-0213-00 Fold Plate Paper Stop Base 82-0157-00 Hardened Flat Washer 84-0065-00 Red #10-32 Thumb Screw 95-0158-00 Scale UNLESS OTHERWISE SPECIFIED Bri-Lin Corporation ALL DIMENSIONS ARE IN INCHES TOLERANCES:...
  • Page 38 7KPlus Exploded Drive Train...
  • Page 39 Retard Assembly Optional Indexing Feed Retard Assembly...

  • Page 40: Addendums

    12. Addendums Over the last several years, the 7KPlus has changed several times. Listed in this addendum are most of the changes that have been made. If the machine being serviced does not have the components listed, contact Infinity Solutions Manufacturing.
  • Page 41 Roll Gears Feed Drive Gear Double Sided Belt Idler Gear Door Switch Feed Pinion Gear Conveyor Pulley Motor Belt 28-0311-00 Motor Pulley and Clutch...
  • Page 42 ITEM PartNo DESCRIPTION QTY. SHEET 2 OF 3 26-0020-00 Spur Gear, Pinion 26-0024-00 Spur Gear, Feed 26-0091-00 Spur Gear, Large Idler 26-0376-00 Spur Gear, Roll Drive 70-0078-00 Feed Idler Bracket 80-0153-00 SHCS 0.250-28 x 1.5 80-0169-00 SHLDR 1/2 x 3/4 x 3/8-16 80-0188-00 Set Screw, SSS #10-32 x 1/4"...
  • Page 43 Double Sided Timing Belt and Drive Pulleys a) Removal • Disconnect the power cord from the machine. 1. Remove the conveyor pulley, motor belt and the gears. (See Section 2.2) 2. Remove the double sided belt. a) Loosen the idler tension bracket and slide the bracket and pulley down to release tension on the belt. b) Remove the idler pulley from the bracket.
  • Page 44 3. Adjustments 1. With the idler bracket loose, slide the idler wheel and bracket up until the belt is tight. Tension the belt so that the belt and gears move freely with minimal resistance. If the belt is too loose excess noise and premature belt failure can occur Feed Gauge ITEM...
  • Page 45 5. Adjustment • Disconnect the power cord from the machine. 1. Remove feed gauge cover 2. Place 1 form on the feed table and hand feed the form into the machine by moving the feed belt with your hand. 3. Pull the paper out of the machine. You should feel resistance, but not too much. Turn the adjustment screw clockwise for less resistance and counter-clockwise for more resistance.
  • Page 46 Sealer Rollers Rolls SHEET 3 OF 3 ITEM PartNo DESCRIPTION Config/ QTY. 25-0377-00 Hardened Race 70-0087-00 Urethane Feed Roll 70-0088-00 Feed Drive Roll 70-0089-00 Hex End Roll 70-0090-00 Conveyor Drive Roll 82-0145-00 0.060" Delrin Thrush Washer 82-0479-00 0.100" Delrin Thrush Washer UNLESS OTHERWISE SPECIFIED Bri-Lin Corporation ALL DIMENSIONS ARE IN INCHES...
  • Page 47 13. Inspect the rolls and delrin spacers for wear and replace any damaged or worn components. a) Clean rolls by wiping down with a household cleaner such as OOPS or the equivalent. 8. Installation 1. Installation is the reverse of removal Note: Make sure the correct spacers are installed on each shaft.
  • Page 48 Phone (866) 427-4546 Fax (603) 332-8043 www.brilininc.com...

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