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MyBinding Plockmatic FTR200 Service Manual

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  • Page 1 Plockmatic FTR200 Trimmer Service Manual Provided By http://www.MyBinding.com http://www.MyBindingBlog.com...
  • Page 2 TRIMMER FTR 200 SERVICE MANUAL 12 February 2007 Subject to change...
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  • Page 4: Table Of Contents

    29 November 2006 TABLE OF CONTENTS 1 INSTALLATION PROCEDURE 1.1 INSTALLATION PROCEDURE ............FTR-1-1 2 PREVENTIVE MAINTENANCE SCHEDULE 2.1 PREVENTIVE MAINTENANCE SCHEDULE ........FTR-2-1 3. REPLACEMENT AND ADJUSTMENT 3.1 COVERS ...................FTR-3-1 3.1.1 FRONT AND REAR COVER ...........FTR-3-1 3.1.2 TOP COVER ................FTR-3-2 3.1.3 BLOWER MOTOR M5 / M6 .............FTR-3-3 3.1.4 INFEED COVER ..............FTR-3-4 3.1.5 LOCKING BRACKET ..............FTR-3-5...
  • Page 5 29 November 2006 6. DETAILED SECTION DESCRIPTIONS 6.1 ELECTRICAL COMPONENT LIST ...........FTR-6-1 6.1.1 REAR VIEW ................FTR-6-2 6.1.2 INFEED VIEW .................FTR-6-3 6.1.3 OUTFEED VIEW ..............FTR-6-4 6.1.4 STOP CARRIAGE VIEW ............FTR-6-5 6.2 BOARD STRUCTURE ..............FTR-6-7 6.2.1 BLOCK DIAGRAM ..............FTR-6-7 6.2.2 CONTROLLER MD6DC ............FTR-6-8 6.2.2 CONTROLLER MD6DC, CONTINUES ........FTR-6-9 6.3 TRIMMING PROCESS ..............

  • Page 6: Installation Procedure

    29 November 2006 INSTALLATION PROCEDURE INSTALLATION PROCEDURE Trimmer installation procedure is located in the Booklet Maker BM 200 Service Manual ( 1.5) FTR-1-1...
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  • Page 8: Preventive Maintenance Schedule

    29 November 2006 PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE SCHEDULE Trimmer preventive maintenance schedule is located in the Booklet Maker BM 200 Service Manual ( FTR-2-1...
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  • Page 10: Replacement And Adjustment

    29 November 2006 COVERS REPLACEMENT AND ADJUSTMENT COVERS 3.1.1 FRONT AND REAR COVER Front Cover Open the Top Cover. Remove screws [A] ( Loosen screws [B] ( Rear Cover Loosen screws [C] ( FTR-3-1...

  • Page 11: Top Cover

    COVERS 29 November 2006 3.1.2 TOP COVER Good Top cover too low Top cover too high Removal Pry off the Gas spring [A] using a screw driver. Remove screws and nuts [B] ( x4). Replacement Reverse the removal procedure. Adjustment Loosen screws and nuts [B] ( x4).

  • Page 12: Blower Motor M5 / M6

    29 November 2006 COVERS 3.1.3 BLOWER MOTOR M5 / M6 Removal Remove blower assy by lifting it straight up [A]. Replacement Reverse the removal procedure. FTR-3-3...

  • Page 13: Infeed Cover

    COVERS 29 November 2006 3.1.4 INFEED COVER Open the Top Cover. Remove Blower assy ( 3.1.3). Disconnect connectors [A] ( x2). Remove Front and Rear cover ( 3.1.1). Remove screws [B] ( x5). Remove screws [C] ( x5). FTR-3-4...

  • Page 14: Locking Bracket

    29 November 2006 COVERS 3.1.5 LOCKING BRACKET Removal Loosen nuts [A] ( x2). Locking bracket will fall down. Replacement Push Trimmer against Booklet Maker. Push up Locking bracket so it latches studs [B]. Tighten nuts [A] ( x2). FTR-3-5...

  • Page 15: Upper Outfeed Cover

    COVERS 29 November 2006 3.1.6 UPPER OUTFEED COVER Remove Belt stacker. Remove Front and Rear cover ( 3.1.1). Open the Top Cover. Remove the Gas spring [A] by prying it off using a screw driver. Remove connector [B] ( x1). Cut cable ties [C] inside cover.

  • Page 16: Interlock Switch S9 &S10

    29 November 2006 COVERS 3.1.7 INTERLOCK SWITCH S9 &S10 Removal Remove connector [B]( x1). Remove nuts [A] ( x2). Replacement Reverse the removal procedure. Adjustment Loosen nuts [A] ( x2). Adjust the interlock so that Top cover actuates interlock switch 2 mm before closed.

  • Page 17: Lower Outfeed Cover

    COVERS 29 November 2006 3.1.8 LOWER OUTFEED COVER Remove Belt stacker ( 3.8.1). Remove Front and Rear cover ( 3.1.1). Remove Protection Cover ( 3.1.9). Loosen screws [A] ( x2). Remove screws [B] ( x4). FTR-3-8...

  • Page 18: Protection Cover

    29 November 2006 COVERS 3.1.9 PROTECTION COVER Replacement Step 1. Replacement Step 2. Removal Lift out scrap paper bin [B]. Remove screws [A] ( x4). Replacement Place the front end of the cover up against the lower knife beam [C]. Push in cover so it hooks onto the screws [D].
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  • Page 20: Area C

    29 November 2006 AREA C AREA C 3.2.1 INFEED SENSOR Q13 Undock the Trimmer. Remove nuts [A] inside bracket holding the Sensor bracket ( x2). Remove connector from the Sensor ( x1). Remove sensor [B]. FTR-3-11...

  • Page 21: Control Switch S2

    AREA C 29 November 2006 3.2.2 CONTROL SWITCH S2 Removal Remove Rear cover ( 3.1.1). Remove connectors [A] ( x2). Remove screws [B] ( x2 ). Replacement Reverse the removal procedure. Adjustment Lift the Infeed shaft. Make sure the Switch activates slightly before the shaft latches in upper posi- tion.

  • Page 22: Control Switch S3

    29 November 2006 AREA C 3.2.3 CONTROL SWITCH S3 Removal Remove Rear cover ( 3.1.1). Remove connector [B] ( X2). Remove screw [A] ( x2). Replacement Reverse the removal procedure. Adjustment Lift the compressing bracket. Make sure the Switch activates approximately 10 mm from where the com- pressing bracket latches in the upper position.

  • Page 23: Transport Motor M1

    AREA C 29 November 2006 3.2.4 TRANSPORT MOTOR M1 Remove Transmission chain ( 3.2.17). Remove Knife support chain ( 3.2.18). Remove connector [A] ( x1). Grab the inner sprocket to pull out the whole sprocket assembly [B]. Remove screws [C] holding the motor ( x3).

  • Page 24: Transport Belt Sensor Q4

    29 November 2006 AREA C 3.2.5 TRANSPORT BELT SENSOR Q4 Removal Remove Rear cover ( 3.1.1). Remove connector [A] ( x1). Remove nut and screw [B] ( x1). Remove bracket [C]. Squeeze the barbs of the sensor to remove. Replacement Reverse the removal procedure NOTE: When tightening nut/screw make sure there is a space between en- coder disc and sensor.

  • Page 25: Trim Knife Motor M2

    AREA C 29 November 2006 3.2.6 TRIM KNIFE MOTOR M2 WARNING Place the safety block [D] between lower knife and upper knife beam. When removing the chain nothing holds upper knife beam and knife in position. Removal Remove Rear cover ( 3.1.1).

  • Page 26: Trim Knife Home Postiton Sensor Q5

    29 November 2006 AREA C 3.2.7 TRIM KNIFE HOME POSTITON SENSOR Q5 Removal Remove Rear cover ( 3.1.1). Remove connector [A] ( x1). Squeze the barbs of the sensor to remove. NOTE: Gently pull bracket [B] to remove. WARNING Stay clear from upper knife. The knife edge may cause serious injuries. Replacement Reverse the removal procedure.

  • Page 27: Trim Knife

    AREA C 29 November 2006 3.2.8 TRIM KNIFE WARNING Stay clear from upper knife. The knife edge may cause serious injuries. Place the safety block [A] between lower knife and upper knife beam. Keep the safety block in that position as much time as possible throughout this procedure.
  • Page 28 29 November 2006 AREA C Replacement Upper knife Move transport protection from the old to the new knife. Clean and apply grease on guide bars [J] and side guides [K]. Fit upper knife onto guide bars [J]. Apply grease on the cup spring washers [F] closest to the knife. Mount screws [E] with nuts [G] ( x6).
  • Page 29 AREA C 29 November 2006 Use a feeler gauge and check that the space [Q] between upper knife and the two red marked reference screws in the middle [P] is 0.50 mm. NOTE: Never touch the red painted reference screws [P]. Adjust the space if necessary with screws [O] ( x2).
  • Page 30 29 November 2006 AREA C 13. Slowly and carefully without paper lower the upper knife by turning crank [R]. Check that the upper knife does not contact the lower knife. In that case, back up the upper knife and start over from step 3. If no contact proceed to the bot- tom position.

  • Page 31: Paper Path & Outfeed Sensor Q6

    AREA C 29 November 2006 3.2.9 PAPER PATH & OUTFEED SENSOR Q6 Remove connector [D] ( x1). Lift up and latch compressing bracket [B]. Remove screws [A] ( x2). Remove screws [C] ( x2). Pull Paper path out through the outfeed. To remove sensor, remove screw [E] ( x1).

  • Page 32: Stop Gate Carriage

    29 November 2006 AREA C 3.2.10 STOP GATE CARRIAGE Removal Before switching off the power, set the Trimmer (Paper size) to A4 / 8.5x11” and Trimming to off. Remove Lower outfeed cover ( 3.1.8). Remove connectors [A] ( x2). Remove connectors [B] ( x2).

  • Page 33: Stop Gate Motor M3 & Sensor Q7

    AREA C 29 November 2006 3.2.11 STOP GATE MOTOR M3 & SENSOR Q7 Removal Remove Stop gate carriage ( 3.2.10). Remove nut [A] ( x1). Remove Crank arm [B]. Remove screws [C] holding the motor ( x4). Loosen set screw [D] ( x1). Replacement Mount the Crank pulley [E] without tightening the set screw [D] ( x1).

  • Page 34: Length Adjustment Motor M4 & Sensor Q12

    29 November 2006 AREA C 3.2.12 LENGTH ADJUSTMENT MOTOR M4 & SENSOR Q12 Remove Stop gate carriage ( 3.2.10). Unhook spring [A]. Remove screws [B] holding the motor ( x4). FTR-3-25...

  • Page 35: Length Adjustment Home Position Switch S11

    AREA C 29 November 2006 3.2.13 LENGTH ADJUSTMENT HOME POSITION SWITCH S11 [Picture 1] [Picture 2] Removal Remove Stop gate carriage ( 3.2.10). Remove screws [B] ( x2). Remove connectors [A] ( x2). Replacement Reverse the removal procedure. Adjustment 1. Place a ruler across the slide rods and up against the flange bushings [Picture 1].

  • Page 36: Lower Outfeed Belts

    29 November 2006 AREA C 3.2.14 LOWER OUTFEED BELTS Removal Remove Stop gate carriage ( 3.2.10). Remove Paper path ( 3.2.9). Remove Transmission chain ( 3.2.17). Remove screws [A] ( x2). Remove e-clip [B] ( x1). Slide Flange bushing [C] towards the center of the shaft and tilt the shaft out through the cut-out in the side frame.

  • Page 37: Upper Outfeed Belts

    AREA C 29 November 2006 3.2.15 UPPER OUTFEED BELTS Removal Remove Belt stacker. Remove Front and Rear cover ( 3.1.1). Remove Transmission chain ( 3.2.17). Unhook springs [A] (x2). Remove screws [B] ( x6). NOTE: Leave the screw at the top on each side for the outfeed cover to pivot around.

  • Page 38: Trim Bin Full Sensor Q8

    29 November 2006 AREA C 3.2.16 TRIM BIN FULL SENSOR Q8 Undock the Trimmer. Remove connector [A] ( x1). Remove screw [B] ( x1). FTR-3-29...

  • Page 39: Transmission Chain

    AREA C 29 November 2006 3.2.17 TRANSMISSION CHAIN WARNING Place the safety block [D] between lower knife and upper knife beam. When removing the chain nothing holds upper knife beam and knife in position. Remove Front cover ( 3.1.1). Remove screws [A] ( x3).

  • Page 40: Knife Support Chain

    29 November 2006 AREA C 3.2.18 KNIFE SUPPORT CHAIN Remove Front cover ( 3.1.1). Remove Transmission chain ( 3.2.17). Loosen screws [A] ( x3). Remove chain from sprocket [B]. Replacement Reverse the removal procedure. Tension the chain so there is no slack when tightening screws [A] ( x3).

  • Page 41: Knife Chain

    AREA C 29 November 2006 3.2.19 KNIFE CHAIN WARNING Place the safety block [D] between lower knife and upper knife beam. When removing the chain nothing holds upper knife beam and knife in position. Removal Remove Rear cover ( 3.1.1). Remove retaining ring [A].

  • Page 42: Infeed Belts

    29 November 2006 AREA C 3.2.20 INFEED BELTS Removal Undock the Trimmer. Remove Infeed cover ( 3.1.4). Remove Front and Rear cover ( 3.1.1). Unhook Transmission chain [E] from sprocket [F]. NOTE: Unhooking chain from outfeed shaft sprockets first to gain more slack. Unhook Springs [A] on both ends of the shaft (x2). Remove screws [B] on both ends of the shaft ( x2) .
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  • Page 44: Pcb

    29 November 2006 3.3.1 MD6DC PCB ”A” A.P4 A.P7 A.P6 A.P11 A.P13 A.P3 A.P14 A.P2 CAUTION ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or com- munications problems. Failure to use proper ESD procedures will cause damage to elec- tronic components (example: PCBs).
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  • Page 46: Troubleshooting

    12 February 2007 FAULT CODE DESCRIPTIONS TROUBLESHOOTING FAULT CODE DESCRIPTIONS Fault Item Fault description Page ..code FTR-001 FTR-M1 Transport motor No displacement pulses FTR-4-2 FTR-002 FTR-M1/M2 Transport motor and Trim knife motor Cycle time out FTR-4-3 FTR-003 FTR-M1 Transport motor Short circuit FTR-4-4 FTR-004 FTR-M1 Transport motor Open circuit...
  • Page 47 FAULT CODE DESCRIPTIONS 12 February 2007 FTR-001 Fault Code FTR-001, indicates that the Transport motor (FTR-M1) does not receive any displace- ment pulses. Initial Actions Check fuse F2 on Transformer. Make sure that the Transport belt sensor (FTR-Q4) is installed correctly ( FTR 3.2.5).
  • Page 48 12 February 2007 FAULT CODE DESCRIPTIONS FTR-002 Fault Code FTR-002, indicates that either the Transport motor (FTR-M1) or the Trim Knife motor (FTR-M2) had a Cycle time out. Initial Actions Check fuse F2 on Transformer. Make sure that the Trimmer knife home position sensor (FTR-Q5) is installed correctly. Procedure Enter the Service mode and select Trimmer knife home position sensor (FTR-Q5) in check sensors.
  • Page 49 FAULT CODE DESCRIPTIONS 12 February 2007 FTR-003 Fault Code FTR-003, indicates that the Transport motor (FTR-M1) has a Short circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M1. Run the Diagnostics again. Fault code FTR-004 (Open circuit) is displayed? Disconnect plug B.P3 from PCB “A”.
  • Page 50 12 February 2007 FAULT CODE DESCRIPTIONS FTR-006 Fault Code FTR-006, indicates that the Trim knife motor (FTR-M2) has a Open circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M2. Enter Service mode and start Trim knife motor (FTR-M2) in check motors. Measure between the orange wire M2 and the violet wire M2 (PWM 36 and ground).
  • Page 51 FAULT CODE DESCRIPTIONS 12 February 2007 FTR-008 Fault Code FTR-008, indicates that the Stop gate motor (FTR-M3) has a Short circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M3. Run the Diagnostics again. Fault code FTR-009 (Open circuit) is displayed? Disconnect plug B.P2 from PCB “A”.
  • Page 52 12 February 2007 FAULT CODE DESCRIPTIONS FTR-011 Fault Code FTR-011, indicates that the Length adjustment motor (FTR-M4) had a Cycle time out. Initial Actions Check fuse F2 on Transformer. Enter the Service mode and select Length adjustment motor (FTR-M4) in check motors. Make sure that the Length adjustment home position switch (FTR-Q131) is installed correctly.
  • Page 53 FAULT CODE DESCRIPTIONS 12 February 2007 FTR-013 Fault Code FTR-013, indicates that the Length adjustment motor (FTR-M4) has an Open circuit. Initial Actions Check fuse F2 on Transformer. Procedure Disconnect the motor plug M4. Enter Service mode and start Length adjustment motor (FTR-M4) in check motors. Measure between the orange wire M4 and the violet wire M4 (PWM 36V and ground).
  • Page 54 12 February 2007 FAULT CODE DESCRIPTIONS FTR-016 Fault Code FTR-016, indicates that the Control switch infeed (FTR-S2) or Control switch outfeed (FTR-S3) is faulty. Initial Actions Make sure that the Infeed shaft and the Outfeed compressing bracket is in it’s lower position. Procedure Enter the Service mode and select Infeed switch (FTR-S2/S3) in check switches.
  • Page 55 FAULT CODE DESCRIPTIONS 12 February 2007 FTR-018 Fault Code FTR-018, indicates that the Trim bin full sensor (FTR-Q8) is faulty. Initial Actions Make sure that the Trim bin full sensor (FTR-Q8) is installed correctly. Procedure 1. Replace sensor FTR-Q8. 2. Disconnect plug B.P13 from PCB “A”. Measure between J13-10 and J13-12 (5V and ground). The voltage is approximately 5 VDC? Replace PCB “A”.
  • Page 56 12 February 2007 FAULT CODE DESCRIPTIONS FTR-152 Fault Code FTR-151, indicates that the Interlock switch is faulty. Initial Actions Check fuse F2 on Transformer. Enter the Service mode and check the Trimmer voltmeter. Power ON and Power OFF the Trimmer (make sure that the Top cover interlock, and the External Interlock Device interlock is interlocked).
  • Page 57 FAULT CODE DESCRIPTIONS 12 February 2007 FTR-203 Fault Code FTR-203, indicates that during Run, the Outfeed sensor trimmer (FTR-Q6), was not blocked within timeout. Initial Actions Check fuse F2 on Transformer. Make sure that the Outfeed sensor trimmer (FTR-Q6) is installed correctly. Ensure that the Outfeed sensor trimmer (FTR-Q6) is clean.
  • Page 58 12 February 2007 FTR-502 Fault Code FTR-502, indicates that the blowers (FTR-M5/M6) do not respond. Initial Actions Check placement of blowers. Make sure blowers are installed correctly. Procedure Enter the Service mode and select blowers Trimmer (FTR-M5/M6) in check motors. Do the blowers work? Go to FTR-014 fault code.
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  • Page 60: Service Tables

    29 November 2006 SERVICE TABLES SERVICE TABLES Trimmer service tables is located in the Booklet Maker BM 200 Service Manual ( FTR-5-1...
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  • Page 62: Detailed Section Descriptions

    29 November 2006 ELECTRICAL COMPONENT LIST DETAILED SECTION DESCRIPTIONS ELECTRICAL COMPONENT LIST Page FTR-M1 Transport motor ................FTR-6-3 / FTR-6-4 FTR-M2 Trim knife motor ................FTR-6-3 / FTR-6-4 FTR-M3 Stop gate motor ................... FTR-6-5 FTR-M4 Length adjustment motor ................FTR-6-5 FTR-M5/M6 Blower motor ....................FTR-6-3 FTR-Q13 Infeed sensor ....................

  • Page 63: Rear View

    ELECTRICAL COMPONENT LIST 29 November 2006 6.1.1 REAR VIEW Counter Safety block for knife FTR-S3 FTR-S2 FTR-Q5 FTR-Q4 MD6DC PCB “A” Stacker COM BM 200 Terminator / COM SQF 200 Receptacle Power Supply Trimmer FTR-6-2...

  • Page 64: Infeed View

    29 November 2006 ELECTRICAL COMPONENT LIST 6.1.2 INFEED VIEW FTR-M5 / M6 Interlock Switch FTR-M1 FTR-S9 / Q130 FTR-M2 FTR-Q13 FTR-Q8 FTR-6-3...

  • Page 65: Outfeed View

    ELECTRICAL COMPONENT LIST 29 November 2006 6.1.3 OUTFEED VIEW FTR-M2 FTR-Q6 FTR-M1 FTR-6-4...

  • Page 66: Stop Carriage View

    29 November 2006 ELECTRICAL COMPONENT LIST 6.1.4 STOP CARRIAGE VIEW FTR-M4 / FTR-S11 FTR-Q7 FTR-M3 FTR-Q12 FTR-6-5...
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  • Page 68: Board Structure

    29 November 2006 BOARD STRUCTURE 6.2.1 BLOCK DIAGRAM FTR-6-7...

  • Page 69: Controller Md6Dc

    29 November 2006 6.2.2 CONTROLLER MD6DC The motor drives: MA-MD are for bi-directional motors with lower current ME is for bi-directional motor with higher current. MF is for one-directional motor with higher current. As the FTR 200 does not have any solenoids, one of the solenoid drives is used for the electro-mechanical counter.

  • Page 70: Controller Md6Dc, Continues

    29 November 2006 6.2.2 CONTROLLER MD6DC, CONTINUES FTR-M2 FTR-M1 FTR-M4 FTR-M5 & FTR-M6 Set counter FTR-M3 ST-M1 FTR-6-9...
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  • Page 72: Trimming Process

    29 November 2006 TRIMMING PROCESS TRIMMING PROCESS 6.3.1 PRINCIPLE OF OPERATION FTR-M2 FTR-Q13 FTR-Q6 FTR-M1 FTR-Q4 FTR-Q5 FTR-6-11...
  • Page 73 TRIMMING PROCESS 29 November 2006 FTR-Q7 FTR-M3 Trimming Booklet maker sends a start signal. The transport motor (FTR-M1) starts and transports the booklet into the machine. The infeed sensor (FTR-Q13) is activated by the booklet. The booklet passes and deactivates the infeed sensor (FTR-Q13). When the booklet hits the stop gate, the transport motor (FTR-M1) stops.

  • Page 74: Size Adjustment

    29 November 2006 TRIMMING PROCESS 6.3.2 SIZE ADJUSTMENT FTR-S11 FTR-M4 & FTR-Q12 Initialization cycle Main power is switched on. Length adjustment motor (FTR-M4) starts. The motor (FTR-M4) moves the stop gate to the smallest booklet size. The motor (FTR-M4) stops when length adjustment home position switch (FTR- S11) is activated.
  • Page 75 TRIMMING PROCESS 29 November 2006 6.3.2 SIZE ADJUSTMENT Initialization cycle Main power is switched on. Length adjustment motor (FTR-M4) starts. The motor (FTR-M4) moves the stop gate to the smallest booklet size. The motor (FTR-M4) stops when length adjustment home position switch (FTR- S11) is activated.

  • Page 76: Specifications Specifications

    29 November 2006 SPECIFICATIONS SPECIFICATIONS Trimmer specifications is located in the Booklet Maker BM 200 Service Manual SPECIFICATIONS) FTR-Spc-1...
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  • Page 78: Wiring Trimmer

    29 November 2006 WIRING Trimmer See pocket at rear of manual for wiring diagrams. FTR-Wir-1...
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