Squarefolder SFM6204 Tag 7 Squarefolder SFM6704 Tag...

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Squarefolder SFM6204 Tag 7 Squarefolder SFM6704 Tag 1 SERVICE MANUAL Source: DBCR-0512-0020-V003 Doc no: DBCR-0512-0020-V005 Rev date: 15 August 2012

Transcript of Squarefolder SFM6204 Tag 7 Squarefolder SFM6704 Tag...

Page 1: Squarefolder SFM6204 Tag 7 Squarefolder SFM6704 Tag 1downloads.canon.com/isg_manuals/Square_Folder_Module_SFM...Squarefolder SFM6204 Tag 7 Squarefolder SFM6704 Tag 1 SERVICE MANUAL

Squarefolder SFM6204 Tag 7

Squarefolder SFM6704 Tag 1

SERVICE MANUAL

Source: DBCR-0512-0020-V003 Doc no: DBCR-0512-0020-V005 Rev date: 15 August 2012

Page 2: Squarefolder SFM6204 Tag 7 Squarefolder SFM6704 Tag 1downloads.canon.com/isg_manuals/Square_Folder_Module_SFM...Squarefolder SFM6204 Tag 7 Squarefolder SFM6704 Tag 1 SERVICE MANUAL

About this manual. Machines have much in common but there are differences because they can be mirrored, have different colours or additional options. Therefore the machine on the pictures in this manual may be different. This machine must be serviced and repaired by a qualified technician.

Safety. Carefully read the Safety Instruction Document (DBCH-0512-0000-V000) before installing, servicing or operating your equipment.

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III

6 August 2010, R 1.8, Rev 1

TABLEOFCONTENTS

1 INSTALLATIONPROCEDURE1.1 INSTALLATION PROCEDURE ........................................................SQF-1-1

2 PREVENTIVEMAINTENANCESCHEDULE2.1 PREVENTIVE MAINTENANCE SCHEDULE ..................................SQF-2-1

3 REPLACEMENTANDADJUSTMENT3.1 COVERS ..........................................................................................SQF-3-1

3.1.1 FRONT COVER ......................................................................SQF-3-13.1.2 REAR COVER ........................................................................SQF-3-23.1.3 INFEED COVER .....................................................................SQF-3-33.1.4 OUTFEED COVER .................................................................SQF-3-43.1.5 TOP COVER ...........................................................................SQF-3-63.1.6 TILT THE MACHINE ...............................................................SQF-3-7

3.2 MOTORS .........................................................................................SQF-3-93.2.1 TRANSPORT BELT MOTOR (M1) ..........................................SQF-3-93.2.2 STOP GATE MOTOR (M2) ...................................................SQF-3-103.2.3 CLAMP MOTOR (M3) ...........................................................SQF-3-113.2.4 ROLLER MOTOR (M4) AND PRESSURE ROLLER .............SQF-3-12

3.3 SENSORS AND SWITCHES .........................................................SQF-3-153.3.1 STOP GATE SENSOR (Q1) ..................................................SQF-3-153.3.2 ROLLER MOTOR FRONT / REAR SENSORS (Q2 AND Q3) .............SQF-3-163.3.3 CLAMP MOTOR HOME POSITON SENSOR (Q4) ..............SQF-3-173.3.4 INFEED / OUTFEED SENSORS (Q5 AND Q7) ....................SQF-3-183.3.5 CLAMP SENSOR (Q6) ..........................................................SQF-3-203.3.6 MOTOR M4 ENCODER SENSOR (Q8) ................................SQF-3-213.3.7 TOP COVER INTERLOCK SWITCHES (S2 & S4) ...............SQF-3-223.3.8 UPPER TRANSPORT BELT CLUTCHES (SOL1 & SOL3) ...SQF-3-233.3.9 LOWER TRANSPORT BELT CLUTCHES (SOL2 & SOL4) ..SQF-3-24

3.4 BELTS ............................................................................................SQF-3-253.4.1 UPPER TRANSPORT BELT .................................................SQF-3-253.4.2 LOWER TRANSPORT BELT ................................................SQF-3-263.4.3 TEFLON TAPE LOWER TRANSPORT BELT ....................SQF-3-29

3.5 MECHANICS .................................................................................SQF-3-313.5.1 SET CLAMPS ........................................................................SQF-3-313.5.2 STOP GATE ..........................................................................SQF-3-34

3.6 PCB ...............................................................................................SQF-3-373.6.1 PCB MD6DC “D” ...................................................................SQF-3-37

3.7 POWER REQUIREMENTS ...........................................................SQF-3-393.7.1 TAPPING THE TRANSFORMER ..........................................SQF-3-39

4.TROUBLESHOOTING4.1 FAULT CODE DESCRIPTIONS.......................................................SQF-4-14.2 BLOWN FUSE CONDITION ..........................................................SQF-4-134.3 LED’S .............................................................................................SQF-4-15

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IV

6 August 2010, R 1.8, Rev 1

4.4 TEST POINTS ...............................................................................SQF-4-174.5 BEST PRACTICE ..........................................................................SQF-4-18

5 SERVICETABLES5.1 SERVICE TABLES ...........................................................................SQF-5-1

6.DETAILEDSECTIONDESCRIPTION6.1 ELECTRICAL COMPONENT LIST ..................................................SQF-6-1

6.1.1 COMPONENT LAYOUT ..........................................................SQF-6-26.2 BOARD STRUCTURE .....................................................SQF-6-5

6.2.1 CONTROLLER MD6DC ..........................................................SQF-6-56.3 PRINCIPLE OF OPERATION ..........................................................SQF-6-7

SPECIFICATIONSSPECIFICATIONS .............................................................................. SQF-Spc-1

WIRINGSquareFolder ....................................................................................... SQF-Wir-1

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SQF-1-1

6 August 2010, R 1.8, Rev 1

Inst

alla

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1 INSTALLATIONPROCEDURE1.1 INSTALLATIONPROCEDURESquareFolder INSTALLATION PROCEDURE is located in the Booklet Maker BLM6200 Service Manual.

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SQF-2-1

6 August 2010, R 1.8, Rev 1

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2 PREVENTIVEMAINTENANCESCHEDULE2.1 PREVENTIVEMAINTENANCESCHEDULESquareFolder PREVENTIVE MAINTENANCE SCHEDULE is located in the Book-let Maker BLM6200 Service Manual.

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SQF-3-1

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6 August 2010, R 1.8, Rev 1

3 REPLACEMENTANDADJUSTMENT3.1 COVERS3.1.1 FRONTCOVER

COVERS

[A]

Removal1. Open top cover.2. Remove screw [A] ( x ).3. Lift and remove cover.

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SQF-3-2

6 August 2010, R 1.8, Rev 1

3.1.2 REARCOVER

[A]

Removal1. Open Top Cover.2. Loosen screw [A] ( x 1 ).3. Close Top Cover.4. Lift up and remove Rear Cover.

COVERS

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SQF-3-3

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6 August 2010, R 1.8, Rev 1

3.1.3 INFEEDCOVER

[A]

Removal1. Remove Front and Rear Cover ( 3.1.1 and 3.1.2 ).2. Open Top cover.3. Remove nuts [A] ( x 4 ).4. Remove nuts and washers [B] and remove locking bracket ( x 2, x 2 ).5. Disconnect sensor connector [C] ( x 1).6. Note the position of the springs to the Upper Transport Belts [D].7. Gently lift Infeed Cover enough to open wiring channels [D].

Replacement4. Reverse the removal procedure. NOTE: Make sure that the springs to the Upper Transport Belts are in correct

position.

[A]

[C]

COVERS

[B]

[D]

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SQF-3-4

6 August 2010, R 1.8, Rev 1COVERS

Removal1. Remove Top cover gas spring lower end from joint [A]. NOTE:Press plastic stud from pivot point.2. Loosen screws [B] ( x 2).3. Remove screws [C] ( x 2).4. Remove upper part of outfeed cover.5. Remove Belt Stacker hangers and washers [D] ( x 2, x 2).6. Remove screws [E] ( x 2).7. Remove screws and washers [F] ( x 2, x 2).8. Lift Out feed cover plates carefully and disconnect wiring to sensor Q7 Pho-

totransistor [G] ( x 1).9. Remove lower part of outfeed cover.

3.1.4 OUTFEEDCOVER

[A]

[B]

[D]

[C]

[F]

[E]

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6 August 2010, R 1.8, Rev 1

[G]

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SQF-3-6

6 August 2010, R 1.8, Rev 1COVERS

3.1.5 TOPCOVER

Removal1. Remove Left Cover (front cover 3.3.1 or rear cover ( 3.3.2 depen-

ding on model).2. Open Top cover.3. Remove Top cover gas spring lower end from joint [A]. NOTE:Press plastic stud from pivot point.4. Remove screws [B] ( x 4). NOTE:There are spacers on the inside and nut plates on the rear side.

[B]

[A]

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SQF-3-7

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6 August 2010, R 1.8, Rev 1

3.1.6 TILTTHEMACHINE

Removal1. Remove Belt stacker.2. Remove the Trim bin.3. Remove Front and Rear cover ( 3.3.1, 3.3.2 ).4. Remove screws [A] ( x 2).

NOTE: Keep the screws. They will be used later.5. Tilt machine by lifting infeed cover.6. Secure machine with the screws [A] removed earlier ( x2).

COVERS

CAUTIONWhenloweringorraisingthemachine,liftininfeedareaonly.

WARNINGBookFoldermayTip.RemoveTopCoverGasSpring 3.1.5)topreventTopCoverfromopeningwhentiltingthemachine.

[A]

Rear viewFront view

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SQF-3-9

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6 August 2010, R 1.8, Rev 1

Removal1. Tilt machine ( 3.1.6).

2. Remove R-pin [A] ( x 1).3. Remove sprocket [B].4. Disconnect the motor connectors ( x 2) .5. Remove screws [C] ( x 4).6. Remove Motor.

Replacement1. Reinstall the motor, and secure it by tighten screws [C] ( x 4).2. Connect the motor connectors ( x 2) . NOTE: The Orange wire on ”+”, and the Violet wire on ”-”.3. Reverse the rest of the removal procedure.

3.2 MOTORS3.2.1 TRANSPORTBELTMOTOR(M1)

MOTORS

M1

[C][A] [B]

Rear view, machine tilted

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SQF-3-10

6 August 2010, R 1.8, Rev 1

3.2.2 STOPGATEMOTOR(M2)

MOTORS

M2

Removal1. Tilt machine ( 3.1.6).3. Loosen cam by loosening allen screw [A] ( x 1).4. Rotate cam to clear sensor bracket and remove.5. Remove screws [B] ( x4).6. Disconnect the Motor ( x 2).7. Remove Motor.

Replacement1. Reinstall the motor, but do not tighten screws [B] ( x 4).2. Connect the motor connectors ( x 2) . NOTE: The Orange wire on ”+”, and the Violet wire on ”-”.3. Reverse the rest of the removal procedure. NOTE: Make sure that allen screw is positioned on motar axle as illustrated [C].

4. PerformStopGateadjustmentB( 3.5.2).

[A] [B] [C]

Rear view, machine tilted

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6 August 2010, R 1.8, Rev 1

3.2.3 CLAMPMOTOR(M3)

Removal1. Remove Outfeed Cover ( 3.1.4 ).2. Remove the E-Clips and Washers [A] ( x 2, x 2).3. Remove the driving disc [B] by loosening allen screw ( x 1).4. Remove the plastic cover [C] and disconnect the motor connectors [D] ( x 2).5. Remove screws [E] holding Motor ( x 4).

Replacement1. Reinstall motor, by tighten screw [C] ( x 4).2. Connect the motor connectors ( x 2) . NOTE: The Orange wire on ”1”, and the Violet wire on ”2”.3. Reverse the rest of the removal procedure.

MOTORS

M3

[A] [E][D] [B][C]

CAUTIONBecarefulnottodamagesensorBF-Q4

Outfeed view

Outfeed view

Top view

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SQF-3-12

6 August 2010, R 1.8, Rev 1MOTORS

3.2.4 ROLLERMOTOR(M4)ANDPRESSUREROLLER

ChangingofwearpointThe wear point is the area on the roller that strikes the Booklet first, as the roller moves from the home position (left and right).

1. Remove outfeed cover ( 3.1.4).2. Move Roller Motor Assembly towards center of clamps.3. Stop Pressure Roller from moving by pressing with your fingers towards the

Pressure Roller and out from the Clamps.4. Move Roll Motor Assembly 20 to 30 mm’s (1”) sideways.

M4

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SQF-3-13

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6 August 2010, R 1.8, Rev 1

Removal1. Remove Outfeed cover ( 3.1.4).2. Disconnect Motor plug M4, and sensor plug J26 [A] from wire harness ( x 2).3. Move Roller Motor assembly towards centre of the clamps.4. Remove E-Clips [B] ( x 2).5. Lift out Motor and Pressure Roller [C] upwards.6. Cut cable ties [D] all the way to connectors, when removing complete Motor.

M4

[B]

O-rings

[C]

[D]

[A]

MOTORS

Front view

Outfeed view

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SQF-3-15

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6 August 2010, R 1.8, Rev 1

Removal1. Tilt machine ( 3.1.6).2. Disconnect connector [A] ( x 1).3. Remove screws [B] ( x 2).3. Loosen screw [C] ( x 1).4. Remove screw [D] and sensor [E].

SENSORS AND SWITCHES

3.3 SENSORSANDSWITCHES3.3.1 STOPGATESENSOR(Q1)

[C]

[A]

[B]

[D][E]

Rear view, machine tilted

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SQF-3-16

6 August 2010, R 1.8, Rev 1

3.3.2 ROLLERMOTORFRONT/REARSENSORS(Q2ANDQ3)

Removal1. Remove Outfeed Cover ( 3.1.4).2. Move Roller Motor assembly towards center of the clamps.3. Disconnect connector [A] ( x 1).4. Remove screw [B] ( x 1).

SENSORS AND SWITCHES

Sensor Q3 Sensor Q2

[B] [A] [B]

Top/outfeed view

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SQF-3-17

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6 August 2010, R 1.8, Rev 1

3.3.3 CLAMPMOTORHOMEPOSITONSENSOR(Q4)

SENSORS AND SWITCHES

Removal1. Remove Outfeed Cover ( 3.1.4).2. Disconnect connector [A] ( x1 ).3. Remove screw [B] ( x1).

[A] [B]

Outfeed view

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SQF-3-18

6 August 2010, R 1.8, Rev 1

RemovalQ5,LED1. Open Top Cover.2. Disconnect connector [A] ( x 1).3. Remove nut [B] ( x 1).4. Remove LED [C].

3.3.4 INFEED/OUTFEEDSENSORS(Q5ANDQ7)

Phototransistor

White

SENSORS AND SWITCHES

InfeedSensorQ5)

[C][A] [B]

[D] [F][E]

LED

Red

Bottom view, machine tilted

RemovalQ5,phototransistor1. Tilt machine ( 3.1.6).2. Disconnect connector [D] ( x 1).3. Remove nut [E] ( x 1).4. Remove Phototransistor [F].

Top view

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SQF-3-19

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6 August 2010, R 1.8, Rev 1 SENSORS AND SWITCHES

RemovalQ7,LED1. Remove Outfeed Cover ( 3.1.4).2. Disconnect connector [A] ( x 1).3. Remove nut [B] ( x 1).4. Remove LED [C].

RemovalQ7,phototransistor1. Tilt machine ( 3.1.6).2. Disconnect connector [D] ( x 1).3. Remove nut [E] ( x 1).4. Remove Phototransistor [F].

OutfeedSensor(Q7)

Phototransistor LED

White Red

[C]

[A]

[B]

[D]

[F]

[E]

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SQF-3-20

6 August 2010, R 1.8, Rev 1SENSORS AND SWITCHES

3.3.5 CLAMPSENSOR(Q6)

[A]

Removal1. Tilt machine ( 3.1.6).2. Disconnect connector [A] ( x 1).3. Remove screw [B] ( x 1).4. Remove sensor [C].

[B] [C]Bottom view, machine tilted

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SQF-3-21

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6 August 2010, R 1.8, Rev 1 SENSORS AND SWITCHES

3.3.6 MOTORM4ENCODERSENSOR(Q8)

Removal1. Remove upper part ot the Outfeed Cover ( 3.1.4).2. Remove screw [A] ( x 1).3. Remove screw and washer [B] ( x 1, x 1).4. Remove safety cover [C].2. Loosen allen screw [D] and remove Tacho Disc [E] ( x 1). 2. Disconnect connector [F] ( x 1).3. Remove sensor [G].

Replacement1. Reverse the removal procedure. NOTE: Install Encoder Disc in centre [H] of slot in sensor.

[D] [F] [G]

[A]

[E]

[H]

[B] [C]

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SQF-3-22

6 August 2010, R 1.8, Rev 1

3.3.7 TOPCOVERINTERLOCKSWITCHES(S2&S4)

Removal1. Remove Outfeed Cover ( 3.1.4).2. Remove nuts [A] and remove switch bracket [B] . 3. Disconnect connectors [C] ( x 4).4. Remove nuts and screws [D] ( x 2, x 2).5. Remove switches SQF-S4 [E] and SQF-S2 [F].

Replacement1. Connect connectors [C] ( x 4). NOTE: Connect the connectors according to figures.2. Reinstall switches SQF-S4 [E] and SQF-S2 [F]. 3. Reinstall the nuts and screws [D] ( x 2, x 2). NOTE: Do not tighten the nuts to hard, that will result in broken switches.4. Reverse the removal procedure. NOTE: When opening the Top Cover, make sure the soft interlock switch [F]

breaks before the hard interlock switch [E].

SENSORS AND SWITCHES

[C][D]

[A] [B]

[E] [F]

SQF-S4 SQF-S2Black

White

Red

Red

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SQF-3-23

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6 August 2010, R 1.8, Rev 1 SENSORS AND SWITCHES

3.3.8 UPPERTRANSPORTBELTCLUTCHES(SOL1&SOL3)

Removal1. Remove Upper Transport Belt ( 3.4.1).2. Remove belt [A].3. Loosen screw [B] ( x 1).4. Remove E-clip [C], plastic washer and bushings ( x1).5. Remove R-pins [D] ( x 1).6. Remove Clutch [E].7. Repeat procedure on the other cluch.

[B] [A]

[C] [D] [E]

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SQF-3-24

6 August 2010, R 1.8, Rev 1SENSORS AND SWITCHES

3.3.9 LOWERTRANSPORTBELTCLUTCHES(SOL2&SOL4)

1. Remove Lower Transport belt drive shaft by following repair 3.4.2 to step 1 to 10 ( 3.4.2).

2. Remove R-pin [M] and remove Clutch [N] ( x 1).3. Repeat procedure on the other clutch.

[H] [I]

[M] [N]

[H][J] [K] [L]

Bottom view, machine tilted

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SQF-3-25

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6 August 2010, R 1.8, Rev 1

3.4 BELTS3.4.1 UPPERTRANSPORTBELT

Removal1. Remove Front and Rear cover ( 3.1.1, 3.1.2 ).2. Loosen Transformer [A] and rotate the fuse plate away from Intermediate gear

[B] ( x 1)( x 1).3. Remove R-pin [B] and remove upper gear [C] ( x 1).4. Remove E-Clip [D] and bushing [E] ( x1).5. Remove E-Clip [F] and bushing [G] ( x1).6. Disconnect connectors [H] ( x 2).7. Move the shaft towards the transformer. Lift up rear end of shaft [I] and remove shaft.

BELTS

[A] [B] [D] [E]

[F] [G] [I] [H]

[C]

Rear view, machine tilted

Front view, machine tilted

Top view

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SQF-3-26

6 August 2010, R 1.8, Rev 1BELTS

Removal1. Tilt machine ( 3.1.6).2. Loosen Transformer [A] and rotate the fuse plate away from Intermediate gear

[B] ( x 1)( x 1).3. Remove R-pin [C] and remove intermediate gear [B] ( x 1).4. Remove E-Clips [D] and bushings [E] ( x2).

3.4.2 LOWERTRANSPORTBELT

[A] [B] [C][D]

[F][G] [G]

[E]Rear view, machine tilted

Front view, machine tilted

5. Disconnect connectors [F] ( x 2).6. Loosen nuts [G] ( x 2).

Bottom view, machine tilted

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6 August 2010, R 1.8, Rev 1

7. Loosen nuts [H] fastening the Sliding plate [I] ( x 4).8. Position Stop gate [J] as illustrated.9. Press shaft [K] downwards until it comes out of the seats and remove shaft.10. Remove shaft [L].

[H] [I] [H][J] [K]

BELTS

[L]

11. Remove nuts [M] ( x 6).12. Disconnect connectors [N] ( x 5).

[M] [M][N][N]

Bottom view, machine tilted

Bottom view, machine tilted

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SQF-3-28

6 August 2010, R 1.8, Rev 1BELTS

13. Remove nuts [O] ( x 2).14. Disconnect connectors [P] ( x 2).15. Cut all cable ties securing wiring harness to the Slide Plate.

16. Gently lift the Slide Plate17. Gently slide off belts.

Bottom view, machine tilted

Top view

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6 August 2010, R 1.8, Rev 1

3.4.3 TEFLONTAPELOWERTRANSPORTBELT

Removal1. Open the Top cover.2. Lift the upper Feed belt assembly.3. Lift the lower Feed belt and remove Teflon tape.

Replacement1. Mount the new teflon tape straps between the cut-outs for the rollers and on

each side of the cut-outs for the cable ties.

BELTS

Top view

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6 August 2010, R 1.8, Rev 1 MECHANICS

3.5 MECHANICS3.5.1 SETCLAMPS

[D]

[B]

Removal1. Remove Outfeed cover ( 3.1.4).2. Remove allen screws [A] for upper and lower Paper Guides ( x 8).3. Remove the upper and lower paper guide.4. Tilt machine ( 3.1.6).5. Remove linkage shafts [B] holding the upper clamp on front side, by removing

E-clip [C] on the side of the linkage shafts which has a chamfered end ( x 1).6. Remove linkage shafts holding the upper clamp on rear side, by removing E-clip on the side of the linkage shafts which has a chamfered end ( x 1).7. Remove the two brass guides [D] on the PCB side of the machine ( x 6).

[C][A]

Outfeed view

Front view

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SQF-3-32

6 August 2010, R 1.8, Rev 1MECHANICS

[E]

8. Remove upper clamp.9. Grab the roller cage [E] (not the motor) and remove the ball bearings from the

rail, (downwards).

[F] [G]

[H]

10. Loosen the lower clamp [F] by tapping gently, using a plastic hammer [G], on lower clamp front side until the spring pressure is relieved.

11. Hold the roller cage down and remove the lower set clamp.

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6 August 2010, R 1.8, Rev 1 MECHANICS

Replacement1. Insert lower clamp [ I ], roller assembly, and springs in the machine. 2. Mount pins [H] centerd in the lower clamp.3. Apply grease on each end of the lower clamp, by the pins.4. Insert upper clamp [J].5. Apply grease on clamp, by brass guides. NOTE: Make sure no grease gets in contact with the roll.6. Grease the upper clamp on the infeed side by the roll assembly’s home position / turning points.7. Mount the linkage shafts [B], to the upper clamp, and the E-clips on both front

and rear side ( x 2). NOTE: Make sure flat end corresponds to flat on linkage.8. Turn linkage to press down the lower clamp [ I ].9. Push lower clamp in position.10. Mount brass guides without tightening the screws ( x 6). NOTE: Grease the brass guides.11. Press the brass guides together and tighten the screws. There should be no

play between guides and clamps ( x 6). CAUTION: The clamps must be centerd in the cut-outs.

12. Turn linkage afterwards to make sure that clamps moves without binding.13. Clean clamps on outfeed side and press area with alcohol fluid. 14. Mount lower paper guide ( x4).15. Mount upper paper guide ( x4).16. Check Set Stop Gate adjustment ( 3.5.2).17. Reverse the removal procedure.

[ I ]

[ J][H]

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SQF-3-34

6 August 2010, R 1.8, Rev 1

3.5.2 STOPGATE

StopGateAdjustmentA

NOTE: Procedure adjusts appearance of SquarteFolded spine of booklet.

1. Enter Service mode ( Service manual BLM6200 5.1).

2. In SFM6204 Service, set ”Adjust mode” to ON ( Service manual BLM6200 5.6 ).

3. Set up the SquareFolder to Mode 1.4. Run 6 sheet booklets of 80 gsm (20lb bond), from the Printer.5. Check appearance of booklets according to pictures above.6. Turn Adjustment Nuts [A] to obtain correct result.

NOTE: Adjustment Nuts can be reached through outfeed cover.7. In SFM6204 Service, set ”Adjust mode” to OFF ( Service manual BLM6200

5.6 ).8. Run 6 sheet booklets of 80 gsm (20lb bond), from the Printer.9. Check appearance of booklets according to pictures above.

[A]

[B]

[C]

[D]

Not Good

Loosen Adjustment Nut

GoodNot Good

Tighten Adjustment Nut

MECHANICS

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6 August 2010, R 1.8, Rev 1 MECHANICS

StopGateAdjustmentB

NOTE: This procedure must be performed if any mechanics in the stopgate have been altered, or if the stop gate motor or stop gate has been replaced.

1. Tilt machine ( 3.1.6).2. Turn Stop Gate Cam using the Stop Gate Motor so that Stop Gate is in upper

position.3. Measure between Lower Clamp [B] and Stop Gate [C] on one side only (which

side does not matter). Distance [D] should be 7.5 ± 0.2 mm.4. Loosen Stop Gate Motor M2 mounting screws and move Stop Gate Motor to

obtain measurement ( x 4).5. Perform Stop Gate Adjustment A.

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6 August 2010, R 1.8, Rev 1 PCB

Removal1. Remove Right Cover (front cover 3.3.1 or rear cover ( 3.3.2 depen-

ding on model).2. Remove all connectors from PCB [A] ( x 8).3. Remove PCB by squeezing barbs [B] on the standoffs ( x4) securing PCB.

REPLACEMENT1. Reverse the removal procedure.

NOTE: Make sure all DIP switches are in off position [C]. NOTE: Make sure correct software version is loaded in the PCB.

3.6 PCB3.6.1 PCBMD6DC“D”

ON

[C]

[A] [B]

CAUTIONESDHazard!ESD(ElectrostaticDischarge)cancausesoftwarecrashes,dataand/orcommunicationsproblems.FailuretouseproperESDpro-cedureswillcausedamagetoelectroniccomponents(example:PCBs).ESDproblemscanbeminimizedbymaintainingallmachinegroundcon-nections,ensuringtheproperhandlingofcircuitboardsandsensors.UseESDprotectionwhenworkingnearPCBs.FailuretouseESDprotectionislikelytoresultinaPCBfailure( 3.1).

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6 August 2010, R 1.8, Rev 1 POWER REQUIREMENTS

3.7 POWERREQUIREMENTS3.7.1 TAPPINGTHETRANSFORMER

Purpose

To be able to change the Transformer setting.

Removal

1. Remove Left Cover (front cover 3.3.1 or rear cover ( 3.3.2 depen-ding on model).

Adjustment

1. Measure the wall outlet voltage. See Booklet Maker service manual section ( 1.1.2 ) for permissible voltage fluctuations.

2. Tap the Transformer to the appropriate setting according to the label on the Transformer by moving cable [A].NOTE: Do not move cable [B].

Continue on next page

[A][B]

Transformer in picture tapped for 230V

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SQF-3-40

6 August 2010, R 1.8, Rev 1

Adjustment,continues

3. If the new tapping is 120V or lower, replace the 230V sticker [C] with the 120V sticker [D].

Replacement

1. Reverse the removal procedure.

[C] [D]

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6 August 2010, R 1.8, Rev 1

4. TROUBLESHOOTING4.1 FAULTCODEDESCRIPTIONSSQF-001 SQF-M1 TransportbeltmotorShortcircuit.............................................SQF-4-2

SQF-002 SQF-M1 TransportbeltmotorOpencircuit..............................................SQF-4-2

SQF-003 SQF-M2 StopgatemotorNodisplacementpulses.................................SQF-4-2

SQF-004 SQF-M2 StopgatemotorShortcircuit.....................................................SQF-4-3

SQF-005 SQF-M2 StopgatemotorOpencircuit.....................................................SQF-4-3

SQF-006 SQF-M2 StopgatemotorCycletimeout..................................................SQF-4-3

SQF-007 SQF-M3 ClampmotorShortcircuit..........................................................SQF-4-4

SQF-008 SQF-M3 ClampmotorOpencircuit...........................................................SQF-4-4

SQF-009 SQF-M3 ClampmotorCycletimeout.......................................................SQF-4-4

SQF-010 SQF-M4 RollermotorShortcircuit...........................................................SQF-4-5

SQF-011 SQF-M4 RollermotorOpencircuit...........................................................SQF-4-5

SQF-012 SQF-M4 RollermotorCycletimeout........................................................SQF-4-6

SQF-013 SQF-M4 RollermotorNodisplacementpulses.......................................SQF-4-7

SQF-014 SQF-Q5 InfeedsensorisFaulty................................................................SQF-4-7

SQF-015 SQF-Q6 ClampsensorisFaulty...............................................................SQF-4-8

SQF-016 SQF-Q7 OutfeedsensorisFaulty.............................................................SQF-4-8

SQF-150 36Vinputlow................................................................................SQF-4-9

SQF-151 36Vinputhigh..............................................................................SQF-4-9

SQF-152 SQF-SW1, 2,3or4 InterlockswitchSquareFolderisFaulty...................................SQF-4-9

SQF-201 SQF-Q5 InfeedsensorwasNotblockedwithintimeout.......................SQF-4-10

SQF-202 SQF-Q5 InfeedsensorwasBlockedexceedingtimeout......................SQF-4-10

SQF-203 SQF-Q6 ClampsensorwasNotblockedwithintimeout......................SQF-4-10

SQF-204 SQF-Q6 ClampsensorwasBlockedexceedingtimeout...................... SQF-4-11

SQF-205 SQF-Q7 OutfeedsensorwasBlockedexceedingtimeout................ SQF-4-11

SQF-206 SQF-Q7 OutfeedsensorwasNotBlockedexceedingtimeout............ SQF-4-11

NoSquarefoldingaction UnitdoesnotSquarefolda4sheetbooklet...................SQF-4-12

FAULT CODE DESCRIPTION

CAUTIONESDHazard!ESD(ElectrostaticDischarge)cancausesoftwarecrashes,dataand/orcommunicationsproblems.FailuretouseproperESDpro-cedureswillcausedamagetoelectroniccomponents(example:PCBs).ESDproblemscanbeminimizedbymaintainingallmachinegroundcon-nections,ensuringtheproperhandlingofcircuitboardsandsensors.UseESDprotectionwhenworkingnearPCBs.FailuretouseESDprotectionislikelytoresultinaPCBfailure( 3.1).

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SQF-4-2

6 August 2010, R 1.8, Rev 1FAULT CODE DESCRIPTION

SQF-001Fault code SQF-001, indicates that the Transport Belt motor (SQF-M1) has a short circuit.InitialActions Check Fuse F2 on the Square Folder Transformer.

ProcedureDisconnect the motor plug M1. Run the Diagnostics again. FaultcodeSQF-002(Opencircuit)isdisplayed?Y N Disconnect plug D.P3 from PCB ”D”. Check wires for Short circuit across leads, the Orange wire M1 to D.P3-6 (violet) and the Violet wire M1 to D.P3-7 (orange). IsthereShortcircuit? Y N Replace PCB ”D”.

Replace wire Harness.

Replace motor SQF-M1.

SQF-002Fault code SQF-002, indicates that the Transport belt motor (SQF-M1) has an Open circuit.InitialActions Check Fuse F2 on the Square Folder Transformer.ProcedureDisconnect the motor plug M1. Enter Service mode and start Transport Belt motor (SQF-M1) in check motors. Measure between the Orange wire M1 and the violet wire M1 (PWM 36V and ground). Thevoltageisapproximately18VDC?Y N Disconnect plug D.P3 from PCB ”D”. Measure between J3-6 and J3-7 (PWM 36V and ground). Thevoltageis approximately18VDC? Y N Replace PCB ”D”.

Replace wire Harness.

Replace motor SQF-M1.

SQF-003Fault code SQF-003, indicates that the Stop gate motor (SQF-M2) does not receive any displace-ment pulses.InitialActions Check Fuse F2 on the Square Folder Transformer. Check Fuse F3 on the Square Folder Transformer. Enter the Service mode and select Stop gate motor (SQF-M2) in check motors. Make sure that the Stop gate sensor (SQF-Q1) is installed correctly.

ProcedureDisconnect the sensor plug Q10 to motor M2. Measure between the red wire Q10 and the black wire Q10 (5V and Signal ground). Thevoltageisapproximately5VDC?Y N Disconnect plug B.P14 from PCB “D”. Measure between the J14-9 and J14-3 (5V and Signal ground). Thevolt ageisapproximately5VDC. Y N Replace PCB “D”.

Replace wire harness.

Disconnect plug B.P14 from PCB “D”. Check wires for Continuity / Short circuit from the grey wire Q10 to B.P14-4, the white wire Q10 to B.P14-7, the black wire Q10 to B.P14-3, the red wire Q10 to B.P14-9. IsthereContinuityandnoShortcircuit?Y N Replace wire harness.

1. Replace motor SQF-M2.2. Replace PCB “D”.

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6 August 2010, R 1.8, Rev 1 FAULT CODE DESCRIPTION

SQF-004Fault code SQF-004, indicates that the Stop gate motor (SQF-M2) has a short circuit.InitialActions Check Fuse F2 on the Square Folder Transformer.

ProcedureDisconnect the motor plug M2. Run the Diagnostics again. FaultcodeSQF-005(Opencircuit)isdisplayed?Y N Disconnect plug D.P2 from PCB ”D”. Check wires for Short circuit across leads, the Orange wire M2 to D.P2-9 (violet) and the Violet wire M1 to D.P2-2 (orange). IsthereShortcircuit? Y N Replace PCB ”D”.

Replace wire Harness.

Replace motor SQF-M2.

SQF-005Fault code SQF-005, indicates that the Stop gate motor (SQF-M2) has an Open circuit.InitialActions Check Fuse F2 on the Square Folder Transformer. Make sure that the allen screw to the white cam is tighten against the flat on the motor shaft.ProcedureDisconnect the motor plug M2. Disconnect plug D.P2. IsthereContinuityandnoShortcircuit?Y N Replace wire Harness.

1. Replace motor SQF-M2.2. Replace PCB ”D”.

SQF-006Fault code SQF-006, indicates that the Stop gate motor (SQF-M2) had a Cycle time out.InitialActions Check Fuse F2 on the Square Folder Transformer. Check Fuse F3 on the Square Folder Transformer. Enter the Service mode and select Stop gate motor (SQF-M2) in check motors. Make sure that the Stop gate motor Home position sensor (SQF-Q1) is installed correctly.

ProcedureEnter the Service mode and select Stop gate motor Home position sensor (SQF-Q1) in check sensors. TheStopgatemo-torHomepositionsensorindicates:1whenthesensorisblocked,and:0whenthesensorisunblocked?Y N 1. Replace sensor SQF-Q1. 2. Disconnect plug D.P13 from PCB ”D”. Measure between J13-1 and J13-3 (5V and ground). The voltageisapproximately5VDC? Y N Replace PCB ”D”.

Disconnect plug from sensor SQF-Q1. Check wire for Continuity / Short circuit from the white wire Q1 to D.P13-3. IsthereContinuityandnoShortcircuit? Y N Replace wire Harness.

Connect plug D.P13 to PCB ”D”. Measure between the red wire Q1 and the black wire Q1 (5V and ground). Thevoltageisapproximately5VDC? Y N Replace wire Harness.

Replace PCB ”D”.

Replace the SQF-M2.

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SQF-4-4

6 August 2010, R 1.8, Rev 1

SQF-009Fault code SQF-009, indicates that the Clamp motor (SQF-M3) had a Cycle time out.InitialActions Check Fuse F2 on the Square Folder Transformer. Check Fuse F3 on the Square Folder Transformer. Enter the Service mode and select Clamp motor (SQF-M3) in check motors. Make sure that the Clamp motor Home position sensor (SQF-Q4) is installed correctly.

ProcedureEnter the Service mode and select Clamp motor Home position sensor (SQF-Q4) in check sensors. TheClampmotorHomepositionsensorindicates:1whenthesensorisblocked,and:0whenthesensorisunblocked?Y N 1. Replace sensor SQF-Q4. 2. Disconnect plug D.P13 and D.P14 from PCB ”D”. Measure between J14-1 and J13-12 (5V and ground). The voltageisapproximately5VDC? Y N Replace PCB ”D”.

Disconnect plug from sensor SQF-Q4. Check wire for Continuity / Short circuit from the white wire Q4 to D.P13-11. IsthereContinuityandnoShortcircuit? Y N Replace wire Harness.

Connect plug D.P13 and D.P14 to PCB ”D”. Measure between the red wire Q4 and the black wire Q4 (5V and ground). Thevoltageisapproximately5VDC? Y N Replace wire Harness.

Replace PCB ”D”.

Replace the SQF-M3.

FAULT CODE DESCRIPTION

SQF-007Fault code SQF-007, indicates that the Clamp motor (SQF-M3) has a short circuit.InitialActions Check Fuse F2 on the Square Folder Transformer.

ProcedureDisconnect the motor plug M3. Run the Diagnostics again. FaultcodeSQF-008(Opencircuit)isdisplayed?Y N Disconnect plug D.P3 from PCB ”D”. Check wires for Short circuit across leads. Check the Orange wire M3 to D.P3-3 (violet) and the Violet wire M3 to D.P3-2 (orange). IsthereShortcircuit? Y N Replace PCB ”D”.

Replace wire Harness.

Replace motor SQF-M3.

SQF-008Fault code SQF-008, indicates that the Clamp motor (SQF-M3) has an Open circuit.InitialActions Check Fuse F2 on the Square Folder Transformer.ProcedureDisconnect the motor plug M3. Disconnect plug D.P3. IsthereContinuityandnoShortcircuit?Y N Replace wire Harness.

1. Replace motor SQF-M3.2. Replace PCB ”D”.

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6 August 2010, R 1.8, Rev 1 FAULT CODE DESCRIPTION

SQF-010Fault code SQF-010, indicates that the Roller motor (SQF-M4) has a short circuit.InitialActions Check Fuse F2 on the Square Folder Transformer.

ProcedureDisconnect the motor plug M4. Run the Diagnostics again. FaultcodeSQF-012(Opencircuit)isdisplayed?Y N Disconnect plug D.P2 from PCB ”D”. Check wires for Short circuit across the leads of the Orange wire M4 to D.P2-12 (violet) and the Violet wire M4 to D.P2-3 (orange). IsthereShortcircuit? Y N Replace PCB ”D”.

Replace wire Harness.

Replace motor SQF-M4.

SQF-011Fault code SQF-011, indicates that the Roller motor (SQF-M4) has an Open circuit.InitialActions Check Fuse F2 on the Square Folder Transformer.ProcedureDisconnect the motor plug M4. Disconnect plug D.P2. IsthereContinuityandnoShortcircuit?Y N Replace wire Harness.

1. Replace motor SQF-M4.2. Replace PCB ”D”.

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SQF-4-6

6 August 2010, R 1.8, Rev 1FAULT CODE DESCRIPTION

SQF-012Fault code SQF-012, indicates that the Roller motor (SQF-M4) had a Cycle time out.InitialActions Check Fuse F2 on the Square Folder Transformer. Check Fuse F3 on the Square Folder Transformer. Enter the Service mode and select Roller motor (SQF-M4) in check motors. Make sure that the Roller motor Rear Home position sensor (SQF-Q2) is installed correctly. Make sure that the Roller motor Front Home position sensor (SQF-Q3) is installed correc-tly.

ProcedureEnter the Service mode and select Roller motor Front Home position sensor (SQF-Q3) in check sensors. TheRollermotorFrontHomepositionsensorindicates:1whenthesensorisblocked,and:0whenthesensorisunblocked?Y N 1. Replace sensor SQF-Q3. 2. Disconnect plug D.P13 and D.P14 from PCB ”D”. Measure between J14-2 and J13-6 (5V and ground). The voltageisapproximately5VDC? Y N Replace PCB ”D”.

Disconnect plug from sensor SQF-Q3. Check wire for Continuity / Short circuit from the white wire Q3 to D.P13-8. IsthereContinuityandnoShortcircuit? Y N Replace wire Harness.

Connect plug D.P13 and D.P14 to PCB ”D”. Measure between the red wire Q3 and the black wire Q3 (5V and ground). Thevoltageisapproximately5VDC? Y N Replace wire Harness.

Replace PCB ”D”.

Enter the Service mode and select Roller motor Rear Home position sensor (SQF-Q2) in check sensors. TheRollermotorRearHomepositionsensorindicates:1whenthesensorisblocked,and:0whenthesensorisunblocked?Y N 1. Replace sensor SQF-Q2. 2. Disconnect plug D.P13 from PCB ”D”. Measure between J13-13 and J13-9 (5V and ground). Thevoltageis approximately5VDC? Y N Replace PCB ”D”.

Disconnect plug from sensor SQF-Q2. Check wire for Continuity / Short circuit from the white wire Q2 to D.P13-5. IsthereContinuityandnoShortcircuit? Y N Replace wire Harness.

Connect plug D.P13 to PCB ”D”. Measure between the red wire Q2 and the black wire Q2 (5V and ground). The voltageisapproximately5VDC? Y N Replace wire Harness.

Replace PCB ”D”.

Pull the motor gently by hand. Areyouabletopullthemotorbackandforthwithoutusingalotofforce?Y N Lubricate where needed.

Replace motor SQF-M4.

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6 August 2010, R 1.8, Rev 1 FAULT CODE DESCRIPTION

SQF-013Fault code SQF-013, indicates that the Roller motor (SQF-M4) do not receive any displacement pulses.InitialActions Check Fuse F2 on the Square Folder Transformer. Enter the Service mode and select Roller motor (SQF-M4) in check motors. Make sure that the Roller motor sensor (SQF-Q8) is installed correctly.

ProcedureDisconnect the sensor plug Q8 to motor SQF-M4. Measure between the yellow wire Q8 and the grey wire Q8 (5V and ground).Thevoltageisapproximately5VDC?Y N Disconnect plug D.P14 from PCB ”D”. Measure between the J14-15 and J14-13 (5V and ground). Thevoltageis approximately5VDC? Y N Replace PCB ”D”.

Replace wire Harness.

Disconnect plug D.P14 from PCB ”D”. Check wires for Continuity / Short circuit from the white wire Q8 to D.P14-14, the grey wire Q8 to D.P14-13, and the yellow wire Q8 to D.P14-15. IsthereContinuityandnoShortcircuit?Y N Replace wire Harness.

1. Replace motor SQF-M4.2. Replace PCB ”D”.

SQF-014Fault code SQF-014, indicates that the Infeed sensor (SQF-Q5) is faulty.InitialActions Make sure that the sensor Is clean. Make sure that the Infeed photo transistor sensor, and the Infeed LED sensor (SQF-Q5) is installed correctly. Check fuse F3 on the Square Folder Transformer.

ProcedureDisconnect plug D.P13 from PCB ”D”. Measure between J13-23 and J13-16 (5V and ground). Thevoltageisapproxima-tely5VDC?Y N Replace PCB ”D”.

Disconnect plug from Infeed LED sensor SQF- Q5. Check wire for Continuity / Short circuit from black wire Q5 to D.P13-16, the red wire Q5 to D.P13-23. IstherecontinuityandnoShortcircuit?Y N Replace wire Harness.

1. Replace Infeed LED sensor Q5.2. Connect plug D.P13 to PCB ”D”. Disconnect plug from Infeed photo transistor sensor SQF-Q5. Measure between black wire Q5 and white wire Q5 (5V and ground). Thevoltageisapproximately5VDC?Y N Disconnect plug J20. Measure between P20-2 and P20-3 (5V and ground) in the plug J20. Thevoltageis approximately5VDC? Y N Disconnect plug D.P13 from PCB ”D”. Measure between J13-24 and J13-25 (5V and ground). The voltageisapproximately5VDC? Y N Replace PCB ”D”.

Replace wire Harness.

Replace wire Harness to Infeed photo transistor sensor Q5.

Replace Infeed photo transistor sensor Q5.

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SQF-4-8

6 August 2010, R 1.8, Rev 1

SQF-016Fault code SQF-016, indicates that the Outfeed sensor (SQF-Q7) is faulty.InitialActions Make sure that the sensor Is clean. Make sure that the Outfeed photo transistor sensor, and the Outfeed LED sensor (SQF-Q7) is installed correctly. Check fuse F3 on the Square Folder Transformer.

ProcedureDisconnect plug D.P13 and D.P14 from PCB ”D”. Measure between J13-17 and J14-10 (5V and ground). Thevoltageisapproximately5VDC?Y N Replace PCB ”D”.

Disconnect plug from Outfeed LED sensor SQF- Q7. Check wire for Continuity / Short circuit from black wire Q7 to D.P14-10, the red wire Q7 to D.P13-17. IstherecontinuityandnoShortcircuit?Y N Replace wire Harness.

1. Replace Outfeed LED sensor Q7.2. Connect plug D.P13 and D.P14 to PCB ”D”. Disconnect plug from Outfeed photo transistor sensor SQF-Q7. Measure between black wire Q7 and white wire Q7 (5V and ground). Thevoltageisapproximately5VDC?Y N Disconnect plug D.P13 from PCB ”D”. Measure between J13-18 and J13-19 (5V and ground). The voltageisapproximately5VDC? Y N Replace PCB ”D”.

Replace wire Harness.

Replace Outfeed photo transistor sensor Q7.

FAULT CODE DESCRIPTION

SQF-015Fault code SQF-015, indicates that the Clamp sensor (SQF-Q6) is faulty.InitialActions Make sure that the Clamp sensor (SQF-Q6) is installed correctly. Make sure that the sensor is clean. Make sure that the Feeding belts are moving smoothly by running Motor M1 according to section 5, Service tables. Check fuse F3 on the Square Folder Transformer.ProcedureDisconnect plug to Clamp sensor SQF-Q6. measure between black wire Q6 and red wire Q6. Thevoltageisapproxima-tely5VDC?Y N Disconnect plug J20. Measure between P20-4 and P20-6 (5V and ground) on plug J20. Thevoltageis approximately5VDC? Y N Disconnect plug D.P13 from PCB ”D”. Measure between J13-20 and J13-22. Thevoltageis approximately5VDC? Y N Replace PCB ”D”.

Replace wire Harness.

Replace wire Harness to Clamp sensor Q6.

Replace Clamp sensor Q6.

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SQF-4-9

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6 August 2010, R 1.8, Rev 1 FAULT CODE DESCRIPTION

Fault Code SQF-150, indicates that the Unreg is low/high.ProcedureMeasure the voltage across the rectifier capacitor. Thevoltageisapproximately>0V?Y N Replace fuse F2.

Measure the voltage across the rectifier capacitor. Thevoltageisapproximately36V?Y N Check transformer tappings ( 3.7.1 ).

Go to SQF-152 fault code.

SQF-152Fault code SQF-152, indicates that one of the interlock switches in the Square Folder is faulty.InitialActions Power OFF the Booklet Maker and make sure the Square Folder is powered off. Check Fuse F2 on the Square Folder Transformer. Check that the Transformer is tapped to the correct voltage according to ( 3.7.1 ).ProcedureMeasure the Interlock switches SW1, SW2, SW3 and SW4 and make sure that they are OK.AreallswitchesOK?Y N Replace the faulty switch.

Make sure Switch SW1, SW2, SW3 and SW4 is interlocked. Power ON the Booklet Maker. Disconnect plug D.P13 and D.P15. Measure J15-2 and J13-14 . Isthere5V?Y N Replace PCB ”D”.

Measure J12-1 and J12-2 on PCB ”D”. Thevoltageisapproximately36VDC?Y N Replace wire Harness.

Replace PCB ”D”.

WARNINGWarningthismeasurementinvolvesliveconductors.Usecautionnottoshortcircuitanyconductors.

SQF-150/151

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SQF-4-10

6 August 2010, R 1.8, Rev 1FAULT CODE DESCRIPTION

SQF-203Fault code SQF-203, indicates that during Run the Clamp sensor (SQF-Q6), was not blocked within timeout.InitialActions Make sure that the sensor Is clean. Make sure that the Clamp sensor (SQF-Q6), is installed correctly. Check fuse F3 on the Square Folder Transformer.

ProcedureEnter the Service mode and select Clamp sensor (SQF-Q6) in check sensors. Block, then unblock, the Q6 sensor with a sheet of paper. TheClampsensor(SQF-Q6)sensorindicates:0whenthesensorisblocked,and:1whenthesensorisnotblocked?Y N Go to SQF-014 fault code.

1. Make sure that nothing interferes with the paper path.2. Make sure that the Feeding belts are moving as they should.3. Clean the Feeding belts.

SQF-202Fault code SQF-202, indicates that at ”initialization” or during Run the Infeed sensor (SQF-Q5), was blocked exceeding timeout.InitialActions Make sure that the sensor Is clean. Make sure that the Infeed sensor (SQF-Q5), is installed correctly. Check fuse F3 on the Square Folder Transformer.

ProcedureEnter the Service mode and select Infeed sensor (SQF-Q5) in check sensors. Block, then unblock, the Q5 sensor with a sheet of paper. TheInfeedsensor(SQF-Q5)sensorindicates:0whenthesensorisblocked,and:1whenthesensorisnotblocked?Y N Go to SQF-013 fault code.

1. Make sure that nothing interferes with the paper path.2. Make sure that the Feeding belts are moving as they should.3. Clean the Feeding belts.

SQF-201Fault code SQF-201, indicates that during Run (Operation) the Infeed sensor (SQF-Q5), was not blocked within timeout after the exit signal from the Trimmer, was detected.InitialActions Make sure that the sensor Is clean. Make sure that the Infeed sensor (SQF-Q5), is installed correctly. Check fuse F3 on the Square Folder Transformer.

ProcedureEnter the Service mode and select Infeed sensor (SQF-Q5) in check sensors. Block, then unblock, the Q5 sensor with a sheet of paper. TheInfeedsensor(SQF-Q5)sensorindicates:0whenthesensorisblocked,and:1whenthesensorisnotblocked?Y N Go to SQF-013 fault code.

Make sure that nothing interferes with the paper coming out from the Trimmer, and going into the Square Folder.

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SQF-4-11

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6 August 2010, R 1.8, Rev 1 FAULT CODE DESCRIPTION

SQF-204Fault code SQF-204, indicates that at ”initialization” or during Run the Clamp sensor (SQF-Q6), was blocked exceeding timeout.InitialActions Make sure that the sensor Is clean. Make sure that the Clamp sensor (SQF-Q6), is installed correctly. Check fuse F3 on the Square Folder Transformer.

ProcedureEnter the Service mode and select Clamp sensor (SQF-Q6) in check sensors. Block, then unblock, the Q6 sensor with a sheet of paper. TheClampsensor(SQF-Q6)sensorindicates:0whenthesensorisblocked,and:1whenthesensorisnotblocked?Y N Go to SQF-014 fault code.

1. Make sure that nothing interferes with the paper path.2. Make sure that the Feeding belts are moving as they should.3. Clean the Feeding belts.

SQF-206Fault code SQF-206, indicates that at ”initialization” or during Run the Outfeed sensor (SQF-Q7), was not blocked exceeding timeout.InitialActions Make sure that the sensor Is clean. Make sure that the Outfeed sensor (SQF-Q7), is installed correctly. Check fuse F3 on the Square Folder Transformer.

ProcedureEnter the Service mode and select Outfeed sensor (SQF-Q7) in check sensors. Block, then unblock, the Q7 sensor with a sheet of paper. TheOutfeedsensor(SQF-Q7)sensorindicates:0whenthesensorisblocked,and:1whenthesensorisnotblocked?Y N Go to SQF-015 fault code.

1. Make sure that nothing interferes with the paper path.2. Make sure that the Stacker belts are moving as they should.3. Clean the Stacker belts.

SQF-205Fault code SQF-205, indicates that at ”initialization” or during Run the Outfeed sensor (SQF-Q7), was blocked exceeding timeout.InitialActions Make sure that the sensor Is clean. Make sure that the Outfeed sensor (SQF-Q7), is installed correctly. Check fuse F3 on the Square Folder Transformer.

ProcedureEnter the Service mode and select Outfeed sensor (SQF-Q7) in check sensors. Block, then unblock, the Q7 sensor with a sheet of paper. TheOutfeedsensor(SQF-Q7)sensorindicates:0whenthesensorisblocked,and:1whenthesensorisnotblocked?Y N Go to SQF-015 fault code.

1. Make sure that nothing interferes with the paper path.

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SQF-4-12

6 August 2010, R 1.8, Rev 1

SquareFolderdoesnotSquarefolda4sheetbookletInitialActions Make sure that the Square Folder is set up to Mode 1.

Procedure

The Specification for the Square Folder Unit is to perform the Square folding action on booklets with approximately 6 sheets/booklet, up to 30 sheet/booklet.

In [Auto] mode, the Booklet maker detects how may sheets there are in the booklet, and automati-cally set the Square Folder to the correct mode.NOTE:When the Square Folder is set to [Auto] and the booklet has less than approximately 6 sheets/booklet, the Square Folder will bypass the Square folding action, transporting the booklet out to the Belt stacker.

To be able to Square fold a booklet with approximately 5 sheet/booklet or less, the Square Folder must be set to [Mode 1].

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SQF-4-13

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6 August 2010, R 1.8, Rev 1 BLOWN FUSE CONDITION

4.2 BLOWNFUSECONDITION

Rating Fuse Symptomatpoweron 115V 210-230V

F1 6.3A 3.15A Power on the Unit, on UI

F2 10A 10A Fault in Area E SQF-150

F3 2A 2A Power on the Unit, on UI

F4 Not in use in the Square Folder configuration

WARNINGONLYUSESLOWBLOWFUSES.

F3

F2

F4

F1

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SQF-4-15

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6 August 2010, R 1.8, Rev 1

4.3 LED’S

D1: Yellow LED flashes when power is on. The flashing indicates that a program is present and functioning. Should a download fail or the 5V be missing, LED would be OFF.

D2: Red LED flashes whenever information is sent or received on the Internal CAN (Central area network). If power is switched on but no operations are performed, LED is OFF.

D15: Green LED permanently OFF. It has no direct function in this configuration.

LED’S

D1

D2

D15

CAUTIONESDHazard!ESD(ElectrostaticDischarge)cancausesoftwarecrashes,dataand/orcommunicationsproblems.FailuretouseproperESDpro-cedureswillcausedamagetoelectroniccomponents(example:PCBs).ESDproblemscanbeminimizedbymaintainingallmachinegroundcon-nections,ensuringtheproperhandlingofcircuitboardsandsensors.UseESDprotectionwhenworkingnearPCBs.FailuretouseESDprotectionislikelytoresultinaPCBfailure( 3.1).

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SQF-4-17

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6 August 2010, R 1.8, Rev 1

4.4 TESTPOINTS

+UNREG: Outgoing unregulated 36V, after interlock. Measure between Test Point +UNREG and Test Point GND/PGND using a voltmeter. The voltage will be shown on the voltmeter unless:- Voltage is outside allowed range 29-43V. Voltage will be 0V.- Machine is interlocked (i.e the top cover is open). Voltage will be 0V.

VCC: Stabilized and rectified 5V made from incoming 10V AC from transformer. Measure between Test Point VCC and Test Point GND/PGND using a voltmeter. The voltage will be shown on the voltmeter. Range 4.9-5.1V.

GND/PGND: Ground /Power Ground is the negative reference when measuring either unregulated 36V (+UNREG) or 5V (VCC).

TEST POINTS

GND/PGND

VCC

+UNREG

CAUTIONESDHazard!ESD(ElectrostaticDischarge)cancausesoftwarecrashes,dataand/orcommunicationsproblems.FailuretouseproperESDpro-cedureswillcausedamagetoelectroniccomponents(example:PCBs).ESDproblemscanbeminimizedbymaintainingallmachinegroundcon-nections,ensuringtheproperhandlingofcircuitboardsandsensors.UseESDprotectionwhenworkingnearPCBs.FailuretouseESDprotectionislikelytoresultinaPCBfailure( 3.1).

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SQF-4-18

6 August 2010, R 1.8, Rev 1

4.5 BESTPRACTICE

Further troubleshooting help can be found in the Best Practice document, available for registered users www.plockmatic.se

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Serv

ice

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es

SQF-5-1

6 August 2010, R 1.8, Rev 1

5 SERVICETABLES5.1 SERVICETABLESSquareFolder SERVICE TABLES is located in the Booklet Maker BLM6200 Ser-vice Manual ( 5)

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SQF-6-1

6 August 2010, R 1.8, Rev 1

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ELECTRICAL COMPONENT LIST

6. DETAILEDSECTIONDESCRIPTION6.1 ELECTRICALCOMPONENTLIST Page SQF-M1 Transportbeltmotor............................................................................6-2SQF-M2 Stopgatemotor...................................................................................6-2SQF-M3 Clampmotor........................................................................................6-2SQF-M4 Rollermotor.........................................................................................6-2

SQF-SOL1

SQF-Q1 Stopgatesensor..................................................................................6-2SQF-Q2 RollermotorRearHomepositionsensor.........................................6-2SQF-Q3 RollermotorFrontHomepositionsensor........................................6-2SQF-Q4 ClampmotorHomepositionsensor.................................................6-2SQF-Q5 Infeedsensor(Phototransistor)..........................................................6-2SQF-Q5 Infeedsensor(LED).............................................................................6-2SQF-Q6 Clampsensor......................................................................................6-2SQF-Q7 Outfeedsensor(Phototransistor).......................................................6-2SQF-Q7 Outfeedsensor(LED).........................................................................6-2SQF-Q8 Rollermotorsensor............................................................................6-2

SQF-SW1,Externalinterlockdevice,interlockswitches....................................6-4SW3

SQF-SW2 Topcoverinterlockswitches..............................................................6-3SW4

PCBMD6DC“D”....................................................................................................6-4

StackerReceptacle.................................................................................................6-3CommunicationBookfolder.................................................................................6-3PowerReceptacle/LineFilter...............................................................................6-3Terminator...............................................................................................................6-3

SetCounter.............................................................................................................6-4Rectifier ...............................................................................................................6-4Transformer.............................................................................................................6-4FuseF16.3Aon115Vmachines,3.15Aon230Vmachines...............................6-3FuseF210A............................................................................................................6-4FuseF32A..............................................................................................................6-4Capacitor ...............................................................................................................6-4

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SQF-6-2

6 August 2010, R 1.8, Rev 1

SQF-Q4SQF-Q2 SQF-Q3

COMPONENT LAYOUT

SQF-Q7 SQF-Q6

SQF-Q5SQF-Q1

SQF-M1

SQF-M3

SQF-M4SQF-Q8

SQF-M2

Top view

Front view

Set Clamp view,seen from Outfeed view

6.1.1 COMPONENTLAYOUT

SQF-SOL2&4 SQF-SOL1&3

SQF-Q10

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SQF-6-3

6 August 2010, R 1.8, Rev 1

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COMPONENT LAYOUT

COM. BLM6200 Terminator

Power recepta-cle / Line Filter

F1

Top cover Interlock switchesSQF-SW2 & SQF-SW4

Rear view

Stacker receptacle

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SQF-6-4

6 August 2010, R 1.8, Rev 1COMPONENT LAYOUT

Set counter PCB MD6DC

Rectifier

Capacitor

Transformer

F3

F2

Top view,Inside machine

Rear view

Front view

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The motor drives:MA-MD are for bi-directional motors with lower currentME is for bi-directional motor with higher current.MF is for one-directional motor with higher current.

One of three solenoid drives is used for the electro-mechanical counter.

6.2 BOARDSTRUCTURE6.2.1 CONTROLLERMD6DC

SOL 3 & 4SOL 1 & 2

Motor SQF-M2Motor SQF-M4Motor ST-M1Motor SQF-M3Motor SQF-M1

SQF-6-5

6 August 2010, R 1.8, Rev 1

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BOARD STRUCTURE

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6.2.1 CONTROLLERMD6DC“D”,CONTINUES

SQF-M3

ST-M1

Set counterSQF-M1

SQF-M4

SQF-M2

SOL 1&2

SOL 3&4

SQF-6-6

6 August 2010, R 1.8, Rev 1BOARD STRUCTURE

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SQF-6-7

6 August 2010, R 1.8, Rev 1

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PRINCIPLE OF OPERATION

6.3 PRINCIPLEOFOPERATION

Squarefoldingsequence:

The stapled and folded booklet, and trimmed if selected, is transported up against the Stop gate in the Square Folder. The booklet is then compressed by the Set Clamps, holding the booklet in place. First the Stop gate moves downward and the Set Clamps compresses the Booklet. The Roller motor moves (rolling) over the spine of the Booklet, pressing it up against the Set clamps, producing the Square fold look.When the Square folding sequence is completed, the Set Clamp moves up and releases its grip on the booklet. The booklet is finally transported out on to the Belt stacker.

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SQF-6-8

6 August 2010, R 1.8, Rev 1PRINCIPLE OF OPERATION

SQF-Q4SQF-Q2 SQF-Q3

SQF-Q7 SQF-Q6

SQF-Q5SQF-Q1

SQF-M1

SQF-M3

SQF-M4 SQF-M2

InitializationCycle:

The Square Folder performs an initialization-check at power on or when one of the interlocks has been opened and closed.Clamp motor SQF-M3 runs until the Clamp motor Home position sensor SQF-Q4 is activated / deactivated, and reverses until sensor SQF-Q4 is activated / deactivated. This is done to open up the gap between the Clamps. Stop Gate motor SQF-M2 runs until the Stop gate sensor SQF-Q1 is activated / deactivated. All the paper path sensors are checked SQF-Q5, SQF-Q6 and SQF-Q7 to make sure that there is no paper in the machine. The Square Folder is now in Ready mode.

Top view

Front view

Set Clamp view,seen from Outfeed view

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SQF-6-9

6 August 2010, R 1.8, Rev 1

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PRINCIPLE OF OPERATION

SQF-Q6

When Infeed sensor SQF-Q5 is activated, the Transport belt Motor SQF-M1 and Solenoids SQF-SOL1-SQF-SOL4 are energized. When Clamp sensor SQF-Q6 is activated, Belt Stacker motor ST-M1 continues to feed out the set.

When Outfeed sensor SQF-Q7 is activated and deactivated, Transport Belt motor SQF-M1, Solenoids SOL1-SOL4 and Stacker motor ST-M1 stops.

InOFFmode:

This mode is for booklets that cannot be Square folded:

SQF-Q7

SQF-M1

SQF-M1

SQF-Q5Front view

Front view

SQF-SOL2&4SQF-SOL1&3

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SQF-6-10

6 August 2010, R 1.8, Rev 1PRINCIPLE OF OPERATION

InMode1:

This mode is for booklets with approximately 6 to 10 sheets of paper that are being Book folded.

When Infeed sensor SQF-Q5 is activated, the Transport belt Motor SQF-M1, Solenoids SQF-SOL1-SQF-SOL4 and Stop gate motor SQF-M2 are energized, moving the Stop gate upwards. Motor SQF-M2 runs until Stop gate sensor SQF-Q1 becomes active, plus a certain amount of pulses. Motor SQF-M1 runs until Clamp sensor SQF-Q6 is activated, plus a certain amount of milliseconds. Solenoids SQF-SOL1-SOL4 deactivate immediately when Clamp sensor SQF-Q6 is activated.

When Transport belt motor SQF-M1 has stopped, Clamp motor SQF-M3 is energized, moving the Clamps downwards. When Clamp motor Home position sensor SQF-Q4 is activated / deactivated, Motor SQF-M3 is denergized. When motor SQF-M3 is denergized, motor SQF-M2 is energized, moving the Stop gate downwards. Motor SQF-M2 will run until sensor SQF-Q1 becomes deactivated. Now the Clamps are holding the booklet, and Stop gate is down.

SQF-Q6 SQF-Q5

SQF-M2 SQF-Q1

SQF-Q3

SQF-Q4

SQF-Q2

SQF-M3SQF-M1

Set Clamp view,seen from Outfeed view

Top view

Front view

Front viewSQF-SOL1&3SQF-SOL2&4

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SQF-6-11

6 August 2010, R 1.8, Rev 1

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PRINCIPLE OF OPERATION

SQF-Q8

When Sensor SQF-Q1 is deactivated, The Roller motor SQF-M4 is energized, and moves over the spine of the Booklet, pressing it up against the Set clamps, producing the Square fold look. The Encoder Sensor Q8 starts counting pulses by reading the Encoder Disc. When the correct number of pulses have been counted, motor SQF-M4 slows down. When Sensor SQF-Q2 or SQF-Q3 is activated, motor SQF-M4 stops.

When Roller motor SQF-M4 has reached it’s home position (SQF-Q2 or SQF-Q3), Clamp motor SQF-M3 is energized, moving the Clamps upwards. Motor SQF-M3 runs until Clamp motor Home position Sensor SQF-Q4 is activated / deactivated. The Clamps are now in their upper position.

When sensor SQF-Q4 is deactivated, Transport Belt motor SQF-M1 and Belt Stacker motor ST-M1 together with Solenoids SQF-SOL1-SQF-SOL4 are energized to feed out the set. When Outfeed sensor SQF-Q7 is Activated / Deactivated, Transport Belt motor SQF-M1 and Stacker motor ST-M1 stop, Solenoids SQF-SOL1-SQF-SOL4 deactivate.

SQF-M4

SQF-Q2

SQF-Q3

SQF-M3

Top view

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SQF-6-12

6 August 2010, R 1.8, Rev 1PRINCIPLE OF OPERATION

InMode2:

This mode is for booklets with approximately 11 to 15 sheets of paper that are being Square folded.

The difference between Mode 1 and Mode 2 is that the Stop gate motor SQF-M2 is stopped a little bit further out from the clamps according to number of pulses from the SQF-M2 motor encoder. The result of this will be that the booklet will be pushed out a little, when being compressed by the Set Clamps, compared to Mode 1.

InMode3:

This mode is for booklets with approximately 16 to 20 sheets of paper that are being Square folded.

The difference between Mode 2 and Mode 3 is that Stop gate Motor SQF-M2 is stopped according to pulses from its encoder a certain distance from the clamps. Also when Roller motor SQF-M4 has reached its home position, the motor SQF-M4 reverses and starts moving in the opposite direction. The result of this is that the spine becomes flatter, compared to Mode 2.

InMode4:

This mode is for booklets with approximately 21 to 25 sheets of paper that are being Square folded.

The difference between Mode 3 and Mode 4 is that Stop gate Motor SQF-M2 is stopped according to pulses from its encoder a certain further distance from the clamps.

InMode5:

This mode is for booklets with approximately 26 to 30 sheets of paper that are being Square folded.

In mode 5 the booklet is clamped and the Roller Motor SQF-M4 makes a double sweep over the spine. Thereafter the clamp is opened, the booklet is pushed forward a little bit, then the clamp is closed again. The Roller Motor then makes a second double sweep over the spine before the booklet is released and transported to the belt stacker.

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SQF-6-13

6 August 2010, R 1.8, Rev 1

Det

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InModeAUTO:

The SQF mode is automatically determined by the member of sheets in the booklet. In all other respects the principle of operation is as already described.

NOTE:The Specification for the Square Folder is to perform the Square folding action on booklets from approximately 6 sheets and up.

NOTE:When the Square folder is set to [Auto] and the booklet has less than ap-proximately 6 sheets/booklet, the Square folder will bypass the Square folding action, transporting the booklet out to the Belt stacker.

PRINCIPLE OF OPERATION

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SQF-Spc-1

6 August 2010, R 1.8, Rev 1

Specificatio

n

SPECIFICATIONSSPECIFICATIONSSquareFolder SPECIFICATIONS is located in the Booklet Maker BLM6200 Ser-vice Manual.

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SQF-Wir-1

6 August 2010, R 1.8, Rev 1

Wiri

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WIRINGSquareFolderSee pocket at rear of manual for wiring diagrams.

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