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Powis Parker 8x Service Manual

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MODEL 8x
DOCUMENT BINDER
S e r v i c e M a n u a l

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Summary of Contents for Powis Parker 8x

  • Page 1 MODEL 8x DOCUMENT BINDER S e r v i c e M a n u a l...
  • Page 2 The information contained in this document is subject to change without notice. Powis Parker makes no warranty of any kind with respect to this information. Powis Parker specifically disclaims the implied warranty of merchantability and fitness for a particular purpose.
  • Page 3 C O N T E N T S 1 SUMMARY 2 OVERVIEW 2.1 Main Components of the FB8x 2.2 Diagram of the User Menu 2.3 System Block Diagram 2.4 Specifications 2.5 Bind Media 2.6 Getting the Best Bind Quality 2.7 Contacting Technical Support 3 REQUIRED SERVICE TOOLS 3.1 Hand Tools 3.2 Tools to Service the Heaters...

  • Page 4: Table Of Contents

    C O N T E N T S 6 SERVICE AND CALIBRATION PROCEDURES (This section contains detailed procedures for removing and installing the specified component on the FB8x) 6.1 Covers 6.1.1 Left Cover 6.1.2 Right Cover 6.1.3 Front Cover 6.2 Cooling Rack 6.3 Controller Assembly 6.3.1 Inspecting the Controller Assembly 6.3.2 Removing and Installing the Controller Assembly...
  • Page 5 After giving the new Model 8x a few test binds you will find that the improvements made to the binder will provide the customer and the service technician with a machine that is both easy to use and easy to service.

  • Page 6: Left Cover

    O V E R V I E W - M a i n C o m p o n e n t s 2 . 1 M A I N C O M P O N E N T S T H E F B 8 x Cooling Rack...
  • Page 7 O V E R V I E W - M a i n C o m p o n e n t s 2 . 1 M A I N C O M P O N E N T S T H E F B 8 x Book Sense Emitter PCA...
  • Page 8 O V E R V I E W - M a i n C o m p o n e n t s 2 . 1 M A I N C O M P O N E N T S T H E F B 8 x Carriage Assembly...

  • Page 9: Controller Assembly

    O V E R V I E W - M a i n C o m p o n e n t s 2 . 1 M A I N C O M P O N E N T S T H E F B 8 x CONTROLLER ASSEMBLY...
  • Page 10 O V E R V I E W - U s e r M e n u 2 . 2 U s e r M e n u This item is present only USER MENU if the STRIP MODE is "L-STRIP ON"...
  • Page 11 O V E R V I E W - S y s t e m B l o c k D i a g r a m 2 . 3 S y s t e m B l o c k D i a g r a m FB8X Service Manual Rev.
  • Page 12 O V E R V I E W - S p e c i f i c a t i o n s 2 . 4 S p e c i f i c a t i o n s Power Requirements: FB8x: 115V (110-125VAC) 50-60 Hz, 8.4 Amps FB8xE &...
  • Page 13 Bind Memory When the machine is turned off and on, the last bind setting will be retained. Binding Widths The Model 8x binder is not compatible with wide L Strips or wide Halfback Covers. (See 2.5 Specifications). Binding Hard Cover Books Use Lx-Strip or L-Strip to bind book blocks to be made into Hard Cover Books.
  • Page 14 O V E R V I E W - G e t t i n g t h e B e s t B i n d Q u a l i t y 2 . 6 G e t t i n g t h e B e s t B i n d...
  • Page 15 T e c h n i c a l S u p p o r t If there are any questions not answered in this manual, please contact the Powis Parker Technical Support Dept: 510-848-2463. FB8X Service Manual Rev. C, 9/28/10...
  • Page 16 O V E R V I E W THIS PAGE IS INTENTIONALLY LEFT BLANK Page 12 FB8X Service Manual Rev. C, 9/28/10...
  • Page 17 R E Q U I R E D S E R V I C E T O O L S When servicing a Model 8x binder the following tools are required: 3.1 HAND TOOLS Phillips Screwdrivers #1 and #2 Needle Nosed Pliers...
  • Page 18 T R O U B L E S H O O T I N G G U I D E 4 . 1 P o w e r P r o b l e m s • NO POWER Possible Cause Solution Power Cord is not securely plugged in.
  • Page 19 T R O U B L E S H O O T I N G G U I D E 4 . 2 E r r o r M e s s a g e s • Error Message: “INSERT BOOK” Possible Cause Solution The operator pressed the Bind button without inserting a...
  • Page 20 T R O U B L E S H O O T I N G G U I D E 4 . 3 M a c h i n e E r r o r s • Error Message: MACHINE ERROR 11, 21, or 31 This error indicates an under-temp error in one of the heaters.
  • Page 21 T R O U B L E S H O O T I N G G U I D E 4 . 3 M a c h i n e E r r o r s • Error Message: MACHINE ERROR 50 This error occurs when a user tries to bind a book and the carriage does not move.
  • Page 22 T R O U B L E S H O O T I N G G U I D E 4 . 3 M a c h i n e E r r o r s • Error Message: MACHINE ERROR 70-75 This error indicates a problem with the A_HI/A_LO values entered into the machine.
  • Page 23 T R O U B L E S H O O T I N G G U I D E 4 . 4 D i s p l a y P r o b l e m s • NO CHARACTER DISPLAYED Possible Cause Solution Display is not connected.
  • Page 24 T R O U B L E S H O O T I N G G U I D E 4 . 5 P o o r B i n d Q u a l i t y • SPINE IS NOT SQUARE Possible Cause Solution The Strip is not folded in a 90 degree angle.
  • Page 25 T R O U B L E S H O O T I N G G U I D E THIS PAGE IS INTENTIONALLY LEFT BLANK FB8X Service Manual Rev. C, 9/28/10 Page 21...
  • Page 26 THIS PAGE IS INTENTIONALLY LEFT BLANK Page 22 FB8X Service Manual Rev. C, 9/28/10...
  • Page 27 S E R V I C E M E N U 5 . 1 A c c e s s i n g t h e S e r v i c e M e n u To access the Service Menu press the OPEN and MENU buttons at the same time while turning the machine on.
  • Page 28 S E R V I C E M E N U 5 . 2 S e r v i c e M e n u D i a g r a m Page 24 FB8X Service Manual Rev. C, 9/28/10...
  • Page 29 S E R V I C E M E N U 5 . 2 S e r v i c e M e n u D i a g r a m FB8X Service Manual Rev. C, 9/28/10 Page 25...
  • Page 30 S E R V I C E M E N U 5 . 3 S e r v i c e M e n u D e s c r i p t i o n s 5.3.1 AUTOCYCLES This option offer two choices for continuous cycling of the machine. It is recommended the while running in either Autocycle mode, that a book or pages be inserted into the binding cavity, secured to the Book Fence with tape.
  • Page 31 S E R V I C E M E N U 5 . 3 S e r v i c e M e n u D e s c r i p t i o n s CAL HEATERS Selecting this menu option will allow you to calibrate all three Heaters. When calibrating the Heaters it is very important that the Heaters are at room temperature.
  • Page 32 S E R V I C E M E N U 5 . 3 S e r v i c e M e n u D e s c r i p t i o n s 5.3.3 SENSORS AC LINE INFO Selecting this menu will display two values: The first value represents the line frequency.
  • Page 33 The diagnostic values are for use by Powis Parker technicians only. SET FAN This menu sets the fan function during heater tests. This menu is for Powis Parker Technicians only. SHOW HEATER SETS This menu displays the thermostat values for the three heaters. The first value is for the Spine Heater. This value should be between 1550 and 2150 .
  • Page 34 S E R V I C E M E N U 5 . 3 S e r v i c e M e n u D e s c r i p t i o n s CHECK HEATER SN This menu displays three numeric readings from the heater temperature sensors.
  • Page 35 S E R V I C E M E N U 5 . 3 S e r v i c e M e n u D e s c r i p t i o n s 5.3.6 MOTORS CARRIAGE In this menu, you can test the function of the Carriage Assembly.
  • Page 36 To turn off the Spine Heater, press the orange OPEN button. Spine Heater Temperature Range Turn off the machine if the temperature 300°F- 330°F exceeds 350°F (177°C). Then contact Powis Parker 149°C-166°C Technical Service. Page 32 FB8X Service Manual Rev. C, 9/28/10...
  • Page 37 To turn off the Bender Heater, press the orange OPEN 107°C-118°C button. Turn off the machine if the temperature exceeds 260° F (127°C). Then contact Powis Parker Technical Service. CHECKING THE BACK HEATER TEMPERATURE 1. Enter HEATERS menu. 2. Select HEATER TEST.
  • Page 38 S E R V I C E M E N U 5 . 4 T E S T I N G A N D C A L I B R A T I O N 5.4.2 CHECKING THE SENSORS To check the sensors, select CHECK SENSORS in the SENSORS menu. A series of numbers will appear representing each of the sensors and switches.
  • Page 39 S E R V I C E M E N U 5 . 4 T E S T I N G A N D C A L I B R A T I O N Checking the Carriage Motor and the Carriage Home Switch Remove the screws attaching the Right Cover but keep the cover plugged into the Wire Harness, taking care the cover does not interfere with the mechanism or...
  • Page 40 If the calibration is unsuccessful, a failure message will appear. If a failure message appears double check and make sure there is nothing blocking the Book Sensor and calibrate again. If you continue to get a failure message, contact Powis Parker technical support.
  • Page 41 S E R V I C E M E N U 5 . 4 T E S T I N G A N D C A L I B R A T I O N 5.4.4 Entering A_HI/A_LO values CAUTION: Entering the wrong values can damage the unit and lead to bind problems.
  • Page 42 S E R V I C E M E N U 5 . 4 T E S T I N G A N D C A L I B R A T I O N 5.4.5 Checking motor functions Checking the Carriage Motor 1.
  • Page 43 S E R V I C E M E N U 5 . 4 T E S T I N G A N D C A L I B R A T I O N Checking the Bender Motor in the BENDER2 menu. 1.
  • Page 44 S E R V I C E M E N U 5 . 4 T E S T I N G A N D C A L I B R A T I O N TOOLS REQUIRED: #1 Phillips Screwdriver, Ohmmeter 5.4.6 Checking the Resistance of the Heater Sensors 1.
  • Page 45 S E R V I C E M E N U 5 . 4 T E S T I N G A N D C A L I B R A T I O N TOOLS REQUIRED: #1 Phillips Screwdriver, Ohmmeter 5.4.7 Checking the Resistance of the Heater Power Connectors 1.
  • Page 46 S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S The focus of these service procedures is to explain how to safely and efficiently remove and replace components of the binder.
  • Page 47 S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S TOOLS REQUIRED: #1 Phillips Screwdriver 6.1.3 Front Cover Fig 2 Fig 1 Removing the Front Cover 1.

  • Page 48: Inspecting The Controller Assembly

    S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 . 3 C o n t r o l l e r A s s e m b l y TOOLS REQUIRED: #2 Phillips Screwdriver, Ground Strap 6.3.1 Inspecting the Controller Assembly...

  • Page 49: Changing The Fuses

    S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 . 3 C o n t r o l l e r A s s e m b l y 6.3.2 Installing the Controller Assembly Fig 2...
  • Page 50 S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 . 4 C a r r i a g e D r i v e TOOLS REQUIRED: #2 Phillips Screwdriver, Needle Nosed Pliers, Diagonal Cutters Removing the Carriage Drive...

  • Page 51: Carriage Drive

    S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 . 4 C a r r i a g e D r i v e TOOLS REQUIRED: #2 Phillips Screwdriver, Needle Nosed Pliers, Diagonal Cutters Installing the Carriage Drive...

  • Page 52: Bender Drive

    S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 . 5 B e n d e r D r i v e TOOLS REQUIRED: #1 &...

  • Page 53: Sensors

    S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 . 6 S e n s o r s TOOLS REQUIRED: #1 &...

  • Page 54: Book Emitter Pca

    S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 . 6 S e n s o r s TOOLS REQUIRED: #1 &...
  • Page 55 S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 . 6 S e n s o r s Replacing the Book Detector requires you to partially disassemble the Carriage Assembly.

  • Page 56: Switches

    S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 . 7 S w i t c h e s TOOLS REQUIRED: #1 &...

  • Page 57: Carriage Clamp Switch

    S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 . 7 S w i t c h e s TOOLS REQUIRED: #1 &...
  • Page 58 S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 . 9 H e a t e r A s s e m b l i e s TOOLS REQUIRED: #1 &...
  • Page 59 S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 . 9 H e a t e r A s s e m b l i e s TOOLS REQUIRED: #1 &...
  • Page 60 S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 . 9 H e a t e r A s s e m b l i e s TOOLS REQUIRED: #1 &...

  • Page 61: Heater Assemblies

    S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 . 9 H e a t e r A s s e m b l i e s TOOLS REQUIRED: #1 &...
  • Page 62 S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 . 1 0 F a n TOOLS REQUIRED: #1 & #2 Phillips Screwdrivers, Needle Nosed Pliers, 2.5mm Hex Key, Diagonal Cutters Removing the Fan Fig 1 1.
  • Page 63 S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 . 1 1 J a w TOOLS REQUIRED: #1 & #2 Phillips Screwdrivers Removing the Jaw Assembly Fig 2 Fig 1...
  • Page 64 S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 . 1 2 G r i p T a p e TOOLS REQUIRED: #1 &...
  • Page 65 S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S THIS PAGE IS INTENTIONALLY LEFT BLANK FB8X Service Manual Rev. C, 9/28/10 Page 61...
  • Page 66 U P G R A D I N G F I R M W A R E 7 . 1 T o o l s R e q u i r e d FB8x P31 Printer Cable (K-551-1685) PC with either Windows 98, 2000, XP, ME, or Vista and a 9-pin com port.
  • Page 67 Manuals and Software. No installation procedure is required for this software. Just save the .exe file in an easy to find location. 1. Download the latest FB8x firmware from the Powis Parker website. The hex file that will contain the new firmware is located on the Dealer Side, in Technical Support, under Manuals and Software.
  • Page 68 U P G R A D I N G F I R M W A R E 7 . 2 U p g r a d i n g F i r m w a r e P r o c e d u r e 4.
  • Page 69 U P G R A D I N G F I R M W A R E 7 . 2 U p g r a d i n g F i r m w a r e P r o c e d u r e 7.
  • Page 70 U P G R A D I N G F I R M W A R E 7 . 2 U p g r a d i n g F i r m w a r e P r o c e d u r e 9.
  • Page 71 U P G R A D I N G F I R M W A R E 7 . 2 U p g r a d i n g F i r m w a r e P r o c e d u r e 11.
  • Page 72 U P G R A D I N G F I R M W A R E THIS PAGE IS INTENTIONALLY LEFT BLANK Page 68 FB8X Service Manual Rev. C, 9/28/10...
  • Page 73 S e r v i c e K i t P a r t N u m b e r s S e r v i c e K i t L i s t i n g F B 8 x P a r t s K-311-4069 Service Kit, Rubber Feet...
  • Page 74 S E R V I C E K I T P I C T U R E S C o v e r s K-410-3996 Service Kit, Cooling Rack K-A4732-02 Service Kit, Plastic Cover Kit Item Qty. Item Qty. Cooling Rack Left Cover Front Cover Skirt...
  • Page 75 S E R V I C E K I T P I C T U R E S E l e c t r o n i c s K-A4730 Service Kit, Sensor Kit K-A3931 Service Kit, Display Assembly Item Qty.

  • Page 76: Bender Assembly

    S E R V I C E K I T P I C T U R E S H e a t e r A s s e m b l i e s K-A4013D Service Kit, Spine Assembly (D & J) K-A4102D Service Kit, Bender Assembly (D &...
  • Page 77 S E R V I C E K I T P I C T U R E S M o t o r s K-A4006 Service Kit, Bender Motor Assembly K-A3933 Service Kit, Carriage Drive Assembly Item Qty. Item Qty. Bender Motor Assembly Carriage Drive Assembly M i s c .
  • Page 78 S E R V I C E K I T P I C T U R E S K i t s K-311-4069 Service Kit, Rubber Feet K-A4687 Service Kit, Spring Kit Item Qty. Item Qty. Spine Spring Rubber Feet Jaw Spring Carriage Spring K-A4711 Service Kit, Small Metal Parts Kit...
  • Page 79 S E R V I C E K I T P I C T U R E S K i t s K-A4708 Service Kit, Grip Tape Kit K-A4709 Service Kit, Fastener Kit Item Qty. Item Qty. Jaw Grip Tape SCREW 3mm X .5 X 6mm PPH Carriage Grip Tape Washer,Fender,#6x1”...
  • Page 80 P I C T U R E S T H E F B 8 x P A R T I A L L Y E X P L O D E D E x p l o d e d V i e w ITEM # DESCRIPTION...
  • Page 81 P I C T U R E S T H E M A C H I N E P A R T I A L L Y E X P L O D E D E x p l o d e d V i e w ITEM # DESCRIPTION...

  • Page 82: Jaw Assembly

    P I C T U R E S T H E M A C H I N E P A R T I A L L Y E X P L O D E D E x p l o d e d V i e w ITEM # DESCRIPTION...
  • Page 83 P I C T U R E S T H E M A C H I N E P A R T I A L L Y E X P L O D E D THIS PAGE IS INTENTIONALLY LEFT BLANK FB8X Service Manual Rev.

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