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Plockmatic CF5030 Service Manual

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COVER FEEDER CF5030
SERVICE MANUAL
25 November 2011
Subject to change

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Summary of Contents for Plockmatic CF5030

  • Page 1 COVER FEEDER CF5030 SERVICE MANUAL 25 November 2011 Subject to change...
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  • Page 3: Table Of Contents

    TABLE OF CONTENTS 1 INSTALLATION PROCEDURE 1.1 INSTALLATION PROCEDURE ............CF-1-1 2 PREVENTIVE MAINTENANCE SCHEDULE 2.1 PREVENTIVE MAINTENANCE SCHEDULE ........CF-2-1 3. REPLACEMENT AND ADJUSTMENT 3.1 COVER FEEDER ................CF-3-1 3.1.1 REMOVE COMPLETE UNIT ............. CF-3-1 3.2 AREA F ....................CF-3-5 3.2.1 EMPTY BIN SENSOR Q31 ............
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  • Page 5: Installation Procedure

    25 November 2011 INSTALLATION PROCEDURE INSTALLATION PROCEDURE Cover Feeder INSTALLATION PROCEDURE is located in the Booklet Maker BK5030 Service Manual ( 1.4) CF-1-1...
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  • Page 7: Preventive Maintenance Schedule

    25 November 2011 PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE SCHEDULE Cover Feeder PREVENTIVE MAINTENANCE SCHEDULE is located in the Book- let Maker BK5030 Service Manual ( CF-2-1...
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  • Page 9: Replacement And Adjustment

    25 November 2011 REPLACEMENT AND ADJUSTMENT COVER FEEDER 3.1.1 REMOVE COMPLETE UNIT Cover Feeder, viewed from Booklet Maker outfeed Cover Feeder, viewed from Booklet Maker front side Remove Top Cover ( BK5030 Service Manual 3.3.5 ). Disconnect motor harness [A] ( x 2).
  • Page 10 COVER FEEDER 25 November 2011 Cover Feeder, viewed from Booklet Maker front side Cover Feeder, viewed from Booklet Maker rear side Remove screws [D] ( x 2). CF-3-2...
  • Page 11 25 November 2011 COVER FEEDER Note the position of the brackets [F] and [G]. Lift the rear end of Cover Feeder and carefully remove the complete unit so that the shaft [F] comes loose from brackets [F] and [G]. NOTE: The shaft [E] must exit the cut-outs in the brackets [F] and [G] in the Top Cover before it can be removed.
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  • Page 13: Area F

    25 November 2011 AREA F AREA F 3.2.1 EMPTY BIN SENSOR Q31 Remove screw [A] ( x1). Gently lift out Sensor Q31 [B] and disconnect connector [C] ( x1). Remove Sensor Q31 [B] ( x1). CF-3-5...

  • Page 14: Paper Width Sensor Q38

    AREA F 25 November 2011 3.2.2 PAPER WIDTH SENSOR Q38 Remove screw [A] ( x1). Gently lift out Sensor Q38 [B] and disconnect connector [C] ( x1). Remove Sensor Q38 [B] ( x1). CF-3-6...

  • Page 15: Feed Roller Assy And Paper Separator Pad

    25 November 2011 AREA F 3.2.3 FEED ROLLER ASSY AND PAPER SEPARATOR PAD 1. Remove the Feed roller assembly [A] by pressing it to the front side according to figure [B]. 2. Lift out the rear side [C] of the Feed roller assembly. 3.

  • Page 16: Feed Motor M15

    AREA F 25 November 2011 3.2.4 FEED MOTOR M15 Removal Remove Rear Top Cover ( Booklet Maker Service Manual 3.3.6). Remove Feed roller assembly ( 3.2.3). Disconnect Connector [A] ( x1). Remove screws [B] ( x3). Remove Feed motor M15. Replacement Reverse the removal procedure.

  • Page 17: Paper Bin Low Sensor Q33

    25 November 2011 AREA F 3.2.5 PAPER BIN LOW SENSOR Q33 Remove Rear Top Cover ( Booklet Maker Service Manual 3.3.6). Disconnect Connector [A] ( x1). Remove screws [B] ( x2). Remove Paper Bin Low Sensor Q33 [C. CF-3-9...

  • Page 18: Drive Motor M16 Assembly

    AREA F 25 November 2011 3.2.6 DRIVE MOTOR M16 ASSEMBLY Removal Remove complete Cover Feeder unit ( 1.1.1). 2. Disconnect Connector [A] ( x1). 3. Remove Drive motor M16 assembly by removing screws [B] ( x2). NOTE: Be careful when removing the Drive motor M16 assembly, so that the Drive Shaft Assembly will not damage the LED sensor CF-Q30 ( 3.2.9).

  • Page 19: Drive Shaft Assembly

    25 November 2011 AREA F 3.2.7 DRIVE SHAFT ASSEMBLY Removal Remove Drive motor M16 assembly ( 3.2.6). Remove the Drive shaft assembly, by sliding it out through the rear frame. Replacement Reverse the removal procedure. Adjustment Adjust the Drive clutch assembly ( 3.2.6).

  • Page 20: Pinch Roll Shaft Assembly

    AREA F 25 November 2011 3.2.8 PINCH ROLL SHAFT ASSEMBLY Remove the Pinch roll shaft assembly by pressing it to the rear side of the Cover Feeder. CF-3-12...

  • Page 21: Paper Path / Dsd Detection Sensor Q30

    25 November 2011 AREA F 3.2.9 PAPER PATH / DSD DETECTION SENSOR Q30 Removal Remove nut [A] ( x1). Disconnect Photo transistor connector [B] ( x1). Remove Photo transistor [C]. Remove Drive shaft assembly ( 3.2.7). Disconnect LED connector [D] ( x1).

  • Page 22: Paper Positioning Sensor Q32

    AREA F 25 November 2011 3.2.10 PAPER POSITIONING SENSOR Q32 Remove the lower paper path ( 3.2.10). Remove screw [A] ( x1). Disconnect connector [B] ( x1). Remove the paper positioning sensor Q32 [C]. Replacement Reverse the removal procedure. CF-3-14...

  • Page 23: Upper And Lower Paper Paths

    25 November 2011 AREA F 3.2.11 UPPER AND LOWER PAPER PATHS 1. Open the Top Cover. 2. Remove Rear Top Cover ( Booklet Maker Service Manual 3.3.6). Upper paper path 1. Remove Spring [A] on the Front and Rear side of the Cover Feeder ( x2).
  • Page 24 BIN EXTENSION PLATE 25 November 2011 3.2.12 BLOWER MOTOR M17 / M18 Remove complete Cover Feeder unit ( 3.1.1). Cut cable tie [A]. Remove screws [B] ( x4). Remove Blower motors M17/M18 [C]. CF-3-16...

  • Page 25: Troubleshooting

    25 November 2011 FAULT CODE DESCRIPTIONS TROUBLESHOOTING FAULT CODE DESCRIPTIONS Fault Item Fault description Page code CF-001 CF-M15 Feed Motor Short Circuit ..............CF-4-2 CF-002 CF-M15 Feed Motor Open Circuit ..............CF-4-2 CF-003 CF-M15 Feed Motor Pulse Time Out Q28 ............CF-4-3 CF-004 CF-M16 Cover Drive Motor Short Circuit ............

  • Page 26: Cf-001 Cf-M15 Feed Motor Short Circuit

    FAULT CODE DESCRIPTIONS 25 November 2011 CF-001 CF-M15 Feed Motor Short Circuit Fault Code indicates that the feed motor CF-M15 has a Short circuit Procedure WARNING Switch off the Main Power Switch and disconnect the Main Power Cord before disconnecting, removing or replacing any electrical components. Disconnect the motor plug M15.

  • Page 27: Cf-003 Cf-M15 Feed Motor Pulse Time Out Q28

    25 November 2011 FAULT CODE DESCRIPTIONS CF-003 CF-M15 Feed Motor Pulse Time Out Q28 This Fault Code indicates that the Feed motor CF-M15 does not receive any encoder pulses Possible failures: - Loose cable - Home position is broken. - Poor mechanic - Broken motor/Encoder Initial Actions •...
  • Page 28 FAULT CODE DESCRIPTIONS 25 November 2011 CF-003 CF-M15 Feed Motor Pulse Time Out Q28, continues Block schematic diagram to CF-003 CF-4-4...

  • Page 29: Cf-004 Cf-M16 Cover Drive Motor Short Circuit

    25 November 2011 FAULT CODE DESCRIPTIONS CF-004 CF-M16 Cover Drive Motor Short Circuit Fault Code indicates that the Cover Drive motor CF-M16 has a Short circuit Procedure WARNING Switch off the Main Power Switch and disconnect the Main Power Cord before disconnecting, removing or replacing any electrical components.

  • Page 30: Cf-006 Cf-M16 Cover Drive Motor Pulse Time Out Q29

    FAULT CODE DESCRIPTIONS 25 November 2011 CF-006 CF-M16 Cover Drive Motor Pulse Time Out Q29 This Fault Code indicates that the Cover Drive Motor CF-M16 does not receive any encoder pulses Possible failures: - Loose cable - Home position is broken. - Poor mechanic - Broken motor/Encoder Initial Actions...

  • Page 31: Cf-007 Cf-M17/18 Blower Motors Open Circuit

    25 November 2011 FAULT CODE DESCRIPTIONS CF-007 CF-M17/18 Blower Motors Open Circuit Fault Code indicates that the blowers CF-M17/18 has an Open circuit. Initial Actions • Check that the Fans are correctly connected. • Make sure that plug H P2 on MD6DC PCB “H” in the Booklet Maker is connected. •...

  • Page 32: Cf-008 Cf-Q31 Empty Bin Sensor Faulty

    FAULT CODE DESCRIPTIONS 25 November 2011 CF-008 CF-Q31 Empty Bin Sensor Faulty Fault Code indicates that the Empty Bin Sensor (Q31) is faulty. Initial Actions • Make sure that Q33 is installed and connected correctly. • Make sure that plug F P6 on Addon PCB “F” in the Booklet Maker is connected. •...

  • Page 33: Cf-009 Cf-Q30 Dsd Sensor Faulty

    25 November 2011 FAULT CODE DESCRIPTIONS CF-009 CF-Q30 DSD Sensor Faulty Fault Code indicates that the DSD/paper path sensor CF-Q30 is faulty. Initial Actions • Make sure that Q30 is installed and connected correctly. • Check calibration of Q30. • Make sure that plug F P1 on Addon PCB “F”...

  • Page 34: Cf-010 Cf-Q32 Paper Positioning Sensor Faulty

    FAULT CODE DESCRIPTIONS 25 November 2011 CF-010 CF-Q32 Paper Positioning Sensor Faulty Fault Code indicates that the Paper Positioning Sensor (Q32) is faulty. Initial Actions • Make sure that Q32 is installed and connected correctly. • Make sure that plug F P6 on Addon PCB “F” in the Booklet Maker is connected. •...

  • Page 35: Cf-011 Cf-Q33 Paper Bin Low Sensor Faulty

    25 November 2011 FAULT CODE DESCRIPTIONS CF-011 CF-Q33 Paper Bin Low Sensor Faulty Fault Code indicates that the Paper Bin Low Sensor (Q33) is faulty. Initial Actions • Make sure that Q33 is installed and connected correctly. • Make sure that plug F P6 on Addon PCB “F” in the Booklet Maker is connected. •...

  • Page 36: Cf-012 Cf-Q38 Paper Format Sensor Faulty

    FAULT CODE DESCRIPTIONS 25 November 2011 CF-012 CF-Q38 Paper Format Sensor Faulty Fault Code indicates that the Paper Bin Low Sensor (Q38) is faulty. Initial Actions • Make sure that Q38 is installed and connected correctly (PL 8.2). • Make sure that plug F P6 on Addon PCB “F” in the Booklet Maker is connected (PL 3.2). •...

  • Page 37: Cf-201 Cf-Q31 Empty Bin Sensor Process

    25 November 2011 FAULT CODE DESCRIPTIONS CF-201 CF-Q31 Empty Bin Sensor process Fault Code indicates that during Run, the Empty bin sensor (Q31) became un¬blocked. Initial Actions • Make sure that the Empty bin sensor Q31 (PL 8.1) is installed correctly. •...

  • Page 38: Cf-204 Cf-Q32 Paper Positioning Sensor Not Activated In Time

    FAULT CODE DESCRIPTIONS 25 November 2011 CF-204 CF-Q32 Paper Positioning Sensor Not activated in time Fault Code indicates that during Run, the Paper positioning sensor (Q32), was not blocked within timeout. Initial Actions • Make sure that the Paper positioning sensor (Q32) is installed correctly (PL 8.0). •...

  • Page 39: Cf-206 Cf-Q30 Dsd Sensor Double Feed

    25 November 2011 FAULT CODE DESCRIPTIONS CF-206 CF-Q30 DSD Sensor Double Feed Fault Code indicates that during Run, the DSD sensor (Q30), stopped the system due to double feed. Initial Actions • Ensure that the DSD Sensor is correctly calibrated. •...

  • Page 40: Cf-502 Wrong Cover/Format

    FAULT CODE DESCRIPTIONS 25 November 2011 CF-502 Wrong Cover/Format Fault Code indicates that the Covers loaded in the Cover Feeder are not the same size as the programmed job. Initial Actions • Make sure the Covers are the same size as the system is set up for. •...

  • Page 41: Service Tables

    25 November 2011 SERVICE TABLES SERVICE TABLES Cover Feeder SERVICE TABLES is located in the Booklet Maker BK5030 Service Manual ( CF-5-1...
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  • Page 43: Detailed Section Descriptions

    25 November 2011 ELECTRICAL COMPONENT LIST DETAILED SECTION DESCRIPTIONS ELECTRICAL COMPONENT LIST Page Grid code CF-M15 Feed motor ..................... CF-6-2 ..N5 CF-M16 Drive motor .................... CF-6-2 ..O5/M5 CF-M17/ Blower motors ..................CF-6-3 ..N5 CF-Q31 Empty bin sensor .................. CF-6-3 ..Q6 CF-Q30 Paper path / DSD detection sensor (Phototransistor) .......

  • Page 44: Rear View

    ELECTRICAL COMPONENT LIST 25 November 2011 6.1.1 REAR VIEW CF-Q33 CF-M16 CF-M15 CF-6-2...

  • Page 45: Outfeed View

    25 November 2011 ELECTRICAL COMPONENT LIST 6.1.2 OUTFEED VIEW CF-Q38 CF-Q31 CF-Q30 CF-Q32 Phototransistor CF-Q30 CF-M17/ CF-6-3...
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  • Page 47: Cover Feeding Process

    25 November 2011 COVER FEEDING PROCESS COVER FEEDING PROCESS 6.2.1 PRINCIPLE OF OPERATION Inserting covers Cover On is selected in the booklet maker UI (operation panel). Empty bin sensor (CF-Q31) detects that sheets are loaded. The operator must press down the bin to load covers. The bin automatically positions the covers against the feed roller.
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  • Page 49: Specifications Specifications

    25 November 2011 SPECIFICATIONS SPECIFICATIONS Cover Feeder SPECIFICATIONS is located in the Booklet Maker BK5030 Service Manual ( SPECIFICATIONS) CF-Spec-1...
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  • Page 51: Wiring

    25 November 2011 WIRING Cover Feeder Included in wiring diagram to BK5030. See separate document. CF-Wir-1...
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