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GERA LadyBird I Service Manual

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LadyBird I Folder
Service Manual
D860101X
March 2014

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Summary of Contents for GERA LadyBird I

  • Page 1 LadyBird I Folder Service Manual D860101X March 2014...

  • Page 2: Table Of Contents

    EFERENCE YMBOLOGY   .......................... IV CRONYMS   ......................IV EFERENCE YMBOLS   ......................IV CHEMATIC YMBOLS   DC V ..................IV OLTAGE EFERENCES   ........................IV BBREVIATIONS   REFERENCE SYMBOLOGY ....................V Ladybird I Folder March 2014 Intro Service Manual...

  • Page 3: About This Documentation

    Section 2 - Repair Analysis Procedure This documentation assumes that the user is familiar with the electrical and mechanical standards that are commonly used throughout the industry, as well as, certain GERA design Section 3 - Fold Quality and documentation conventions.

  • Page 4: How To Use This Documentation

    It also includes specific information that is pertinent to the operation of the machine, but will not be found in any other part of the service documentation. This information may include Ladybird I Folder March 2014 Intro...

  • Page 5: Reference Symbology

    Volts Direct Current These symbols represent various electrical and mechanical components or devices that are Adjustment commonly found In GERA equipment. These symbols are included as an aid to understanding the representations used in the Circuit Diagrams (CDs). Table 1 General Acronyms...

  • Page 6: Reference Symbology

    Plug I Jack Connector and pin number Switch/relay contacts with momentary contacts shown normally closed. Motor Connectors numbering Motor This symbol indicates the numbering of the connector pins Thermistor Thermistor Bead, used to sense temperature Ladybird I Folder March 2014 Intro Service Manual...
  • Page 7 Measurements of logic levels must be made with reference to the specified ground point, unless some other point is referenced in a diagnostic procedure. Nominal Voltage Logic State Actual Voltage Ranges +5 VDC +4.8 VDC to +5.2 VDC Table 3 Ladybird I Folder March 2014 Intro Service Manual...
  • Page 8 SERVICE CALL PROCEDURE ................. 1-1   SERVICE CALL PROCEDURES ..................1-2   INITIAL ACTION ......................1-2   ....................... 1-3 OLDER EGISTRATION   SYSTEM CHECKOUT...................... 1-3   CSE C ...................... 1-3 SCALATION Ladybird I Folder March 2014 Service Manual SERVICE CALL PROCEDURE...

  • Page 9: Service Call Procedure

    Section Generic RAP status after a POST Fold Quality • Error Alarm Final Actions describing what fold process error occurs by fold a copy -Go to the Section 2 Contents Ladybird I Folder March 2014 Service Manual SERVICE CALL PROCEDURE...

  • Page 10: Folder Registration

    After the folder installation procedure is performed it is mandatory to perform the Folder Registration. 1. Make sure that the Product has been registered on the GERA web site and store a copy At the end of the Installation Procedure in Service Manual Section 6 CSE must perform the of the form in the folder.
  • Page 11 RAPS   FOLDER ENTRANCE ALARM RAP (ALL)   FAN FOLDER ALARM RAP (ALL)   CROSS ALARM RAP (ALL)   GENERIC RAPS   Generic RAP 1   POWER OFF RAP Ladybird I Folder March 2014 REPAIR ANALYSIS PROCEDURE Service Manual...

  • Page 12: How To Read This Section

    FAN ALARM 2 Beeps CSE to detects if output are operating CROSS ALARM 3 Beeps Ladybird I Folder March 2014 REPAIR ANALYSIS PROCEDURE Service Manual...

  • Page 13: Status Message Raps

    Controller. Is sensor signal output changing status? Main Controller J6 pin 1 and 4 (high > 9Vdc ) ? If no before change Main Controller pwb open call to Gera Service Team by filling Problem Report Form available at http://www.gera.it/wp- content/uploads/report_form/PROBLEM_REPORT_FORM_ladybird.pdf...

  • Page 14: Fan Folder Lower Pocket Sensor Covered Rap (All)

    If no before change Main Controller pwb open call to Gera Service Team by filling Problem Report Form available at http://www.gera.it/wp- Please check the paper quality if is within the specification then please open call to Gera content/uploads/report_form/PROBLEM_REPORT_FORM_ladybird.pdf Service Team by filling...

  • Page 15: Fan Folder Alarm Rap (All)

    Check the Electric Diagram for Power Supply missed output and/or open circuit till Open call to Gera Service Team by filling Problem Report Form available at to Stepper Motor drive PWBs and stepper motors. http://www.gera.it/wp- Check the [CC] on the...

  • Page 16: Generic Raps

    Troubleshoot connector J16 flat cable Replace the Power Supply. If the folder does not work open after the Power Open call to Gera Service Team by filling Problem Report Form available at Supply replacement call to Gera Service Team by filling Problem Report Form http://www.gera.it/wp-...
  • Page 17 Folding Quality   INITIALIZATION PROCEDURE ..................3-2   FOLD DEFECTS ........................3-2   FOLD QUALITY DEFINITION ..................3-2   FOLD QUALITY RAPS ....................... 3-3   FQ 1 FOLD SKEW ......................3-3   FQ 2 FOLD DAMAGE ......................3-3   FQ 3 FOLD DIMENSIONS ....................3-4  ...

  • Page 18: Initialization Procedure

    Fold quality definition Initialization Procedure The following terms are some of the most commonly used terms that describe fold quality Prior to troubleshooting fold quality defects, insure that the following parameters are correct: problems. • Check that the print exits correctly from the printer, without dog-ears, wrinkles or curl. •...

  • Page 19: Fold Quality Raps

    Fold quality RAPS FQ 2 FOLD DAMAGE FQ 1 FOLD SKEW Defect Probable Cause Corrective actions Defect Probable Cause Corrective actions A. Check the print does not have dog- A. Printer defect ears before entering the Folder.. Fan dog-ears A. Incorrect Infeed Grupo print transportation A.

  • Page 20: Fq 3 Fold Dimensions

    FQ 4 FOLD OUTPUT FQ 3 FOLD DIMENSIONS Defect Probable Cause Corrective actions Defect Probable Cause Corrective actions A. Incorrect fold setup A. Enter Folder Adjustment Addresses A. Incorrect feeding direction or A. Check correctly Title block wrong title block position. position Quick guide B.
  • Page 21 Repair and Adjustments     REPAIR AND ADJUSTMENTS .................. 4-1   1. FOLDER REPS ......................4-2   REP 1.1 UPPER INFEED GROUP OVERTURN ............4-2   REP 1.2 LEFT COVER REMOVAL ................4-2   REP 1.3 RIGHT COVER REMOVAL ................4-3  ...
  • Page 22 1. FOLDER REPS REP 1.2 LEFT COVER REMOVAL 1. Switch off the folder 2. Perform Rep 1.1 In feed Group Overturn REP 1.1 UPPER INFEED GROUP OVERTURN 3. Unscrew the upper fixing screw and loose the two lower fixing screws 4.
  • Page 23 REP 1.3 RIGHT COVER REMOVAL REP 1.4 POWER SUPPLY FRONT COVER REMOVAL Before open the Power Supply Front Cover that’s advisable to lift up the mobile blue 1. Switch off the folder collector to avoid it obstacles the access to the lower panel. Then, remove the Front Tray 2.
  • Page 24 REP 1.5 POWER SUPPLY REAR COVER REMOVAL 1. Switch off the folder and disconnect the Plug 2. Remove the Plate showed below by unscrewing the two fixing screws Figure 4- 5 Power Supply Rear Cover Removal Ladybird Folder Mar 2014 Service Manual REPAIR AND ADJUSTMENTS...
  • Page 25 2. FOLDER ADJUSTMENTS ADJ 1.1 Mobile Roller Right Side ADJ 1.2 Mobile Roller Left Side Purpose Purpose Adjust the Mobile Roller distance in the right side Adjust the Mobile Roller distance in the left side Adjustment Adjustment DO NOT OPERATE ON THE MOBILE DO NOT OPERATE ON THE MOBILE ROLLER ADJUSTMENT...
  • Page 26 ADJ 1.4 INFEED GROUP PARALLELISM ADJ 1.3 FRONT RULE Purpose Before to perform the Adjustment 1.3 check the parallelism between the infeed group both Purpose side and the printer exit. Adjust through the Front Rule the paper infeed if there’s skew. Adjustment Adjustment Adjust the height rule...
  • Page 27 3. PROGRAM ADJUSTMENT PROCEDURE ADJ 1.2 PROGRAM P3 (305) and P4 (297) CROSS ADJ 1.1 PROGRAM P1 (210) and P2 (190) FAN This adjustment is both for program P1 210 mm fan and program P2 190 mm fan Program P3: 305 mm Cross Fold Size Panel Address...
  • Page 28 Spare Parts List     PL 0.1 SENSORS ...........................5-2     PL 0.2 ELECTRONIC PARTS .......................5-3     PL 0.3 MOTORS ..........................5-4     PL 0.4 KIT ............................5-5 Ladybird Folder March 2014 SPARE PARTS LIST Service Manual...
  • Page 29 PL 0.1 SENSORS 2. [CNF] 3. [CS] 1.[CT] ITEM CODE DESCRIPTION C695515X Standard Lateral Sensor 2,5,6 C695412X Standard Frontal Sensor 3,7,8 C695419X Barrier Sensor C850405X Datalogic Lateral Sensor ITEM DESCRIPTION 4. [CA] Start toothed rollers Sensor No Corss Sensor Start Feeding Sensor 5.
  • Page 30 PL 0.2 ELECTRONIC PARTS ITEM CODE DESCRIPTION C940403R POWER SUPPLY 230v C340418X RELAY 24VDC C960423R PWB MAIN CONTROLLER REV. 3 C960403R DRIVE CONTROLLER C940405R STEPPING MOTOR DRIVE NDC 06 Ladybird Folder March 2014 Service Manual SPARE PARTS LIST...
  • Page 31 PL 0.3 MOTORS DESCRIPTION ITEM CODE FEDING MOTOR C860405X FLAP MOTOR CONVEY MOTOR MAIN MOTOR E1 SOLENOIDE 1. [M1.] 4. [M3] 2. [MT] 3. [M2.] 5. [….] Ladybird Folder March 2014 Service Manual SPARE PARTS LIST...
  • Page 32 PL 0.4 CODE DESCRIPTION CARE PACK Ladybird Folder March 2014 Service Manual SPARE PARTS LIST...
  • Page 33 860 SERVICE MANUAL - 5 SPARE PARTS...
  • Page 34 General Procedure     GENERAL PROCEDURE ..................6-1   SPECIFICATIONS ......................6-2   Floor space Requirements ....................................................6-2   Technical specifications ....................................................6-2   CONTROL PANEL ......................6-3   Folding Programs ......................................................6-3   PWB......................6-4 ELECTRONIC   Main Controller PWB ...................................................... 6-4  ...
  • Page 35 SPECIFICATIONS Technical specifications Floor space Requirements • Voltage Requirements: 115V - 2A (60Hz) 230V - 1A (50Hz) A = 600 mm / 23 ½ inches B = 600 mm / 23 ½ inches Audible Noise C = 600 mm / 23 ½ inches Average Continuous D = 400 mm / 15 ½...
  • Page 36 CONTROL PANEL Folding Programs The GERA Ladybird Folder Control Panel contains two keys and five indicator lights. The four lower ones show the current folding program both with solid or blinking indicator light The folding program indicated are different according to the market the folder is intended for.
  • Page 37 Key Reset AMP 4x1 Input C3 AMP 4x1 NDC 06 Dimensions (mm) 93.5 x 101 x 25 Serial Port for Gera Download software J7 / J9 AMP 4x1 Diagnostic & Adjustment Tool connection Working Temp. +5°C÷ +45°C E1 / MT...
  • Page 38 JC 11 CONNECTOR The Cable from the Printer into the Folder through the Connector JC11 is for the information necessary between Folder and Printer: stop the Printer with Folder Alarm, Cut Signal and Starting Folding Process. JC11 ITEM on JC11 DESCRIPTION A, B Switch Alarm Printer...
  • Page 39 DIAGNOSTIC Folder configuration “Download Utility Rel 2.5” Download the GERA UTILITY 2.5 from GERA web site and install it Firmware Download the zipped file who contains defaults values ini file, parameters and firmware “ Parameter and Ini 1.14” Input / Output Test...
  • Page 40 Every 15000 meters folded: Maintenance activities Check & Clean MAINTENANCE Every 60000 meters folded: Maintenance activities Life Part Replacement The CSE has to perform other activities every multiple of 15000 and 60000 meters folded. The folder demands activity of cure and maintenance apt to maintain good functionality and performance.
  • Page 41 If two LED is lit on, do the upgrading procedure again “Download Utility Rel 2.5” Download the GERA UTILITY 2.5 from GERA web site and install it Folder Adjustment Firmware Download the zipped file who contains defaults values ini file, parameters and firmware “...
  • Page 42 Change Tag Index TAG: Introduction CLASS: MFG SERIAL N°: 860010010 The purpose of this section is to provide a listing of the significant changes made to the Folder that NAME: C1C – CC distance. changed the form, fit, function, and/or serviceability of the Folder, PURPOSE: Improve the ansa and get a better infeed through steel ball instead of rollers.
  • Page 43 Ladybird Folder 03-Mar-2014 Service Manual 6-10 GENERAL PROCEDURE...
  • Page 44 Wiring Data 1 FOLDER WIRING DATA....................7-2 BSD 1.1 E ................7-2 LECTRICAL IAGRAM Ladybird Folder March 2014 Service Manual WIRING DATA...
  • Page 45 1 FOLDER WIRING DATA BSD 1.1 ELECTRICAL MAIN DIAGRAM Ladybird Folder March 2014 Service Manual WIRING DATA...

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