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Replacement

Adjustment

29 November 2006

FTR-3-9

3.1.9 PROTECTION COVER

COVERS

Removal

1. Lift out scrap paper bin [B].

2. Remove screws [A] ( x4).

Replacement

1. Place the front end of the cover up against the lower knife beam [C].

2. Push in cover so it hooks onto the screws [D].

3. Mount screws [A] ( x4).

[A]

[B]

[C]

Replacement Step 1.

[D]

Replacement Step 2.

Summary of Contents for Plockmatic FTR 200

Page 1: ...Provided By http www MyBinding com http www MyBindingBlog com Plockmatic FTR200 Trimmer Service Manual ...

Page 2: ...TRIMMER FTR 200 SERVICE MANUAL 12 February 2007 Subject to change ...

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Page 4: ... S3 FTR 3 13 3 2 4 TRANSPORT MOTOR M1 FTR 3 14 3 2 5 TRANSPORT BELT SENSOR Q4 FTR 3 15 3 2 6 TRIM KNIFE MOTOR M2 FTR 3 16 3 2 7 TRIM KNIFE HOME POSTITON SENSOR Q5 FTR 3 17 3 2 8 TRIM KNIFE FTR 3 18 3 2 9 PAPER PATH OUTFEED SENSOR Q6 FTR 3 22 3 2 10 STOP GATE CARRIAGE FTR 3 23 3 2 11 STOP GATE MOTOR M3 SENSOR Q7 FTR 3 24 3 2 12 LENGTH ADJUSTMENT MOTOR M4 SENSOR Q12 FTR 3 25 3 2 13 LENGTH ADJUSTMENT...

Page 5: ...TR 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 FTR 6 11 6 3 1 PRINCIPLE OF OPERATION FTR 6 11 6 3 2 SIZE ADJUSTMENT FTR 6 13 6 3 2 SIZE ADJUSTMENT FTR 6 14 SPECIFICATIONS SPECIFICATIONS FTR Spc 1 WIRING Trimmer FTR Wir 1 ...

Page 6: ...FTR 1 1 29 November 2006 Installation 1 INSTALLATION PROCEDURE 1 1 INSTALLATION PROCEDURE Trimmer installation procedure is located in the Booklet Maker BM 200 Service Manual 1 5 ...

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Page 8: ...1 29 November 2006 Preventive Maintenance 2 PREVENTIVE MAINTENANCE SCHEDULE 2 1 PREVENTIVE MAINTENANCE SCHEDULE Trimmer preventive maintenance schedule is located in the Booklet Maker BM 200 Service Manual 2 ...

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Page 10: ...stment 29 November 2006 FTR 3 1 COVERS 3 REPLACEMENT AND ADJUSTMENT 3 1 COVERS 3 1 1 FRONT AND REAR COVER Rear Cover 1 Loosen screws C x3 Front Cover 1 Open the Top Cover 2 Remove screws A x3 3 Loosen screws B x2 B A C ...

Page 11: ...driver 2 Remove screws and nuts B x4 x4 Replacement 1 Reverse the removal procedure Adjustment 1 Loosen screws and nuts B x4 x4 2 Adjust Top cover so frame edge C is aligned with top of the hinge D See drawings above 3 Tighten screws and nuts C x4 x4 Bad Top cover too low Bad Top cover too high Good D C ...

Page 12: ...Replacement Adjustment 29 November 2006 FTR 3 3 3 1 3 BLOWER MOTOR M5 M6 COVERS Removal 1 Remove blower assy by lifting it straight up A Replacement 1 Reverse the removal procedure A ...

Page 13: ... 4 29 November 2006 3 1 4 INFEED COVER COVERS A 1 Open the Top Cover 2 Remove Blower assy 3 1 3 2 Disconnect connectors A x2 3 Remove Front and Rear cover 3 1 1 4 Remove screws B x5 5 Remove screws C x5 B C ...

Page 14: ...ember 2006 FTR 3 5 3 1 5 LOCKING BRACKET COVERS A B Removal 1 Loosen nuts A x2 2 Locking bracket will fall down Replacement 1 Push Trimmer against Booklet Maker 2 Push up Locking bracket so it latches studs B 3 Tighten nuts A x2 B ...

Page 15: ...VERS 1 Remove Belt stacker 2 Remove Front and Rear cover 3 1 1 3 Open the Top Cover 4 Remove the Gas spring A by prying it off using a screw driver 5 Remove connector B x1 6 Cut cable ties C inside cover 7 Remove screws D x5 8 Remove screws E x5 A C B D E ...

Page 16: ...the interlock so that Top cover actuates interlock switch 2 mm before closed NOTE Make sure both rubber dampers contact the front cover when closed 3 Tighten nuts A x2 A B WARNING Overriding or cheating the interlock allows the FTR 200 system to operate with the top cover open which can result in personal injury Never give the operator access to the cheater or show how ovverriding the interlock sy...

Page 17: ...FTR 3 8 29 November 2006 3 1 8 LOWER OUTFEED COVER COVERS 1 Remove Belt stacker 3 8 1 2 Remove Front and Rear cover 3 1 1 3 Remove Protection Cover 3 1 9 4 Loosen screws A x2 5 Remove screws B x4 B A B ...

Page 18: ...N COVER COVERS Removal 1 Lift out scrap paper bin B 2 Remove screws A x4 Replacement 1 Place the front end of the cover up against the lower knife beam C 2 Push in cover so it hooks onto the screws D 3 Mount screws A x4 A B C Replacement Step 1 D Replacement Step 2 ...

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Page 20: ...ustment 29 November 2006 FTR 3 11 3 2 AREA C 3 2 1 INFEED SENSOR Q13 AREA C 1 Undock the Trimmer 2 Remove nuts A inside bracket holding the Sensor bracket x2 3 Remove connector from the Sensor x1 4 Remove sensor B A B ...

Page 21: ... connectors A x2 3 Remove screws B x2 Replacement 1 Reverse the removal procedure Adjustment 1 Lift the Infeed shaft 2 Make sure the Switch activates slightly before the shaft latches in upper posi tion 3 To adjust loosen screws B x2 4 Reposition switch to obtain adjustment 5 Tighten screws B x2 A B ...

Page 22: ...tor B X2 3 Remove screw A x2 Replacement 1 Reverse the removal procedure Adjustment 1 Lift the compressing bracket 2 Make sure the Switch activates approximately 10 mm from where the com pressing bracket latches in the upper position 3 To adjust loosen screws A x2 4 Reposition switch to obtain adjustment 5 Tighten screws A x2 A B ...

Page 23: ...emove Transmission chain 3 2 17 2 Remove Knife support chain 3 2 18 3 Remove connector A x1 4 Grab the inner sprocket to pull out the whole sprocket assembly B 5 Remove screws C holding the motor x3 NOTE Hold the spacers between motor and frame when removing screws C ...

Page 24: ...s of the sensor to remove Replacement 1 Reverse the removal procedure NOTE When tightening nut screw make sure there is a space between en coder disc and sensor 2 Enter service program mode and start the belts motor M1 Check speed m s is registered Service Manual BM 200 5 1 1 5 1 2 3 If no or erratic speed loosen screw nut B x1 x1 4 Reposition sensor to obtain correct speed registration 5 Tighten ...

Page 25: ... 5 Remove sprocket F 6 Remove screws A holding the motor x3 Replacement 1 If it is difficult to mount sprocket F remove master link B 2 Reverse the removal procedure 3 Tension the chain so there is no slack when tightening screws A x3 B A C E F 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 D ...

Page 26: ...move C D Replacement 1 Reverse the removal procedure 2 Enter service program mode to check that sensor Q5 changes state when blocked unblocked Service Manual BM 200 5 1 1 5 1 2 NOTE Do not cheat the interlock 3 Move the Upper knife by turning crank C using a 13 mm wrench 4 Check on the LCD that sensor Q5 changes state when blocked unblocked by actuators D WARNING Stay clear from upper knife The kn...

Page 27: ...Remove the infeed cover 3 1 4 5 Remove protection cover 3 1 9 Removal Upper knife 1 Remove screws B x3 2 Remove knife protection plate C 3 Move transport protection from the new to the old knife or use the transport protection attached behind the front cover 4 Remove the e clip D from the middle plunger to release the Set clamp x1 5 Remove screws E and cup spring washers x6 NOTE When removing scre...

Page 28: ...mount it on the old knife 5 Mount knife protection plate C 6 Mount the set clamp in position with e clip D x1 Replacement Lower knife 1 Place the lower knife onto the lower knife beam 2 Apply grease on both washers 3 Mount screws I x2 and cup spring washers 4 Mount screws H x4 K J O N L H M L N I E F B D G C M Adjustment 1 Turn screws E so there is no tension and no play between cup spring wash er...

Page 29: ...turning crank R using a 13 mm wrench NOTE When bringing the Upper knife down make sure it does not touch the Lower knife 10 Gently push in the Lower knife against the Upper knife NOTE Listen that it touches on both sides 11 Raise the upper knife to the top position by turning crank R 12 Tighten screws I H x6 NOTE Tighten a little at first according to the sequence 1 6 Then tighten a lit tle harder...

Page 30: ...ect the 20 sheet booklet the same way If the set is not correctly cut on one of the ends loosen the five screws I H on the bad end and keep the one screw I tightened at the good end Turn screw M on the bad end 1 36 revolution or 10 clockwise x1 16 Repeat from step 11 until trim result is perfect 17 If not correctly cut in the middle loosen the four screws H and keep the screws I tightened Turn scr...

Page 31: ... PAPER PATH OUTFEED SENSOR Q6 AREA C 1 Remove connector D x1 2 Lift up and latch compressing bracket B 3 Remove screws A x2 4 Remove screws C x2 5 Pull Paper path out through the outfeed 6 To remove sensor remove screw E x1 A C B D E ...

Page 32: ... cover 3 1 8 3 Remove connectors A x2 4 Remove connectors B x2 5 Remove connector C x1 6 Pull out the Carriage gently A B C D CAUTION When removing the Carriage watch out so the motor connectors B C do not get damaged by the side frame cut outs Replacement 1 When positioning the carriage in place make sure the two sliding rods and the gear rack enters their holes and slot 2 Reverse the removal pro...

Page 33: ...x4 5 Loosen set screw D x1 Replacement 1 Mount the Crank pulley E without tightening the set screw D x1 2 Mount motor with screws C x4 3 Mount Crank arm B 4 Tightening nut A x1 NOTE Make sure play for Crank arm B is maintained 5 Position the Crank pulley E so it is aligned with Crank arm B 6 Tighten set screw D x1 on the flat of the shaft 7 Reinstall Stop gate carriage 3 2 10 A D C B E ...

Page 34: ...Replacement Adjustment 29 November 2006 FTR 3 25 3 2 12 LENGTH ADJUSTMENT MOTOR M4 SENSOR Q12 AREA C 1 Remove Stop gate carriage 3 2 10 2 Unhook spring A 3 Remove screws B holding the motor x4 A B ...

Page 35: ...B x2 3 Remove connectors A x2 Replacement 1 Reverse the removal procedure Adjustment 1 Place a ruler across the slide rods and up against the flange bushings Picture 1 2 Position the switch so it is activated by the ruler and so there is a 0 5 mm 0 2 mm gap between switch body and ruler Picture 2 3 Tighten screws B x2 A B Picture 1 Picture 2 ...

Page 36: ...3 2 17 4 Remove screws A x2 5 Remove e clip B x1 6 Slide Flange bushing C towards the center of the shaft and tilt the shaft out through the cut out in the side frame Replacement 1 Reverse the removal procedure Adjustment 1 Loosen screws A x2 2 The belts should be adjusted so they have no slack and even tension 3 Pull shaft D to obtain adjustment and tighten screws B x2 A B A C D ...

Page 37: ...e nylon washer C x2 Unhook link arm D x2 Remove needle bearing C x2 7 Remove e clip E x2 8 Pull out shaft F 9 Remove e clips G x2 inside frames 10 Slide Flange bushings G towards the center of the shaft and pull out the whole assembly th rough the outfeed 11 Loosen screws H x4 and remove belts Adjustment 1 The belts should be adjusted so they have no slack and even tension 2 Pull runner pulleys I ...

Page 38: ...Replacement Adjustment 29 November 2006 FTR 3 29 3 2 16 TRIM BIN FULL SENSOR Q8 AREA C A B 1 Undock the Trimmer 2 Remove connector A x1 3 Remove screw B x1 ...

Page 39: ...ce the safety block D between lower knife and upper knife beam When removing the chain nothing holds upper knife beam and knife in position D A B C 1 Remove Front cover 3 1 1 2 Remove screws A x3 3 Remove bracket B 4 Pull Tensioner C to release tension when removing chain ...

Page 40: ...KNIFE SUPPORT CHAIN AREA C A B 1 Remove Front cover 3 1 1 2 Remove Transmission chain 3 2 17 3 Loosen screws A x3 4 Remove chain from sprocket B Replacement 1 Reverse the removal procedure 2 Tension the chain so there is no slack when tightening screws A x3 ...

Page 41: ... Remove sprocket C Replacement 1 If it is difficult to mount sprocket C remove master link E 2 Reverse the removal procedure 3 Tension the chain so there is no slack when tightening screws B x3 E B A C 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 D ...

Page 42: ... Remove Belts D x4 from Lever shaft H NOTE Move the belts to one end and the lever shaft to the opposite end 9 Remove e clip C and slide flange bushing towards the center of the shaft x1 10 Tilt the shaft out through the cut out in the side frame on that end to remove the Belts D x4 Replacement 1 Reverse the removal procedure Adjustment 1 Loosen nuts B x2 slightly 2 Place a piece of paper 80 gsm b...

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Page 44: ...the system refering to the latest Technical Bulletin Download software if needed Service Manual BM 200 5 2 4 Reinstall Rear cover 3 1 1 ON 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 ESD problems can be minimized by maintaining all machine...

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Page 46: ... Short circuit FTR 4 7 FTR 013 FTR M4 Stop gate positioning motor Open circuit FTR 4 8 FTR 014 FTR M5 M6 Blower motor s Open circuit FTR 4 8 FTR 015 FTR Q13 Infeed sensor is Faulty FTR 4 8 FTR 016 FTR S2 S3 Control switch infeed or out feed Faulty FTR 4 9 FTR 017 FTR Q6 Outfeed sensor Trimmer is Faulty FTR 4 9 FTR 018 FTR Q8 Trim bin full sensor is Faulty FTR 4 10 FTR 150 36V Input low FTR 4 10 FT...

Page 47: ...13 Item 17 Y N 1 Check transmission 3 2 17 2 Replace motor FTR M1 1 Replace sensor FTR Q4 2 Disconnect plug B P14 from PCB A Measure between J14 13 and J14 15 5V and ground The voltage is approximately 5 VDC Y N Replace PCB A Disconnect plug from sensor FTR Q4 Check wires for Continuity Short circuit from the white wire Q4 to B P14 14 Is there Continuity and no Short circuit Y N Replace Wire Harne...

Page 48: ...ely 5 VDC Y N Replace wire Harness Replace PCB A Enter the Service mode and select Transport motor FTR M1 and Trim Knife motor FTR M2 in check motors Both motors energizes Y N Disconnect the motor plug M1 to Transport Knife motor FTR M1 Enter the Service mode and start Transport motor FTR M1 in check motors Measure between the orange wire M1 and the violet wire M1 PWM 36V and ground The voltage is...

Page 49: ... F2 on Transformer Procedure Disconnect the motor plug M1 Run the Diagnostics again Fault code FTR 004 Open circuit is displayed Y N Disconnect plug B P3 from PCB A Check wires for Short circuit across leads the orange wire M1 to B P3 3 violet and the violet wire M1 to B P3 2 orange Is there Short circuit Y N Replace PCB A Replace wire Harness Replace motor FTR M1 FTR 005 Fault Code FTR 005 indica...

Page 50: ...r FTR Q7 is installed correctly Procedure Enter the Service mode and select Paper stop gate home position sensor FTR Q7 in check sensors The Paper stop gate home position sensor indicates 1 when the sensor is blocked and 0 when the sensor is unblocked Y N 1 Replace sensor FTR Q7 2 Disconnect plug B P13 from PCB A Measure between J13 7 and J13 9 5V and ground The voltage is approximately 5 VDC Y N ...

Page 51: ...ce motor FTR M4 2 Replace PCB A FTR 009 Fault Code FTR 009 indicates that the Stop gate motor FTR M3 has a Open circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M3 Enter Service mode and start Stop gate motor FTR M3 in check motors Measure between the orange wire M3 and the violet wire M3 PWM 36V and ground The voltage is approximately 36 VDC Y N Disconnect ...

Page 52: ... PCB A Measure between the white wire Q131 and the black wire Q131 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness 1 Replace switch FTR Q131 2 Replace PCB A Enter the Service mode and select Length adjustment motor FTR M4 in check motors The motor energizes Y N Replace motor FTR M4 2 Check the allen screw on the cam to the Stop gate push rod 1 Lubricate were needed FAULT ...

Page 53: ...015 indicates that the Infeed sensor FTR Q13 is faulty Procedure Enter the Service mode and select Infeed sensor FTR Q13 in check sensors The Infeed sensor indicates 1 activated and 0 deactivated Y N Disconnect the connector to sensor Q13 Measure between the wires to sensor Q13 5V and ground The voltage is approximately 5 VDC Y N 1 Replace PCB A 2 Replace wire harness Replace Infeed sensor FTR Q13...

Page 54: ...place wire Harness Connect plug B P13 to PCB A Measure between the red wire Q6 and the black wire Q6 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness Replace PCB A 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 ...

Page 55: ... Power ON the Booklet Maker Measure between A J12 1 and A J12 2 in the FTR 200 The voltage is approximately 36V Y N Replace the FTR 200 wire harness Replace PCB A 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 ...

Page 56: ...ver interlock and the External Interlock Device interlock is interlocked Procedure Measure the Interlock switch S9 and S10 and make sure that they are OK Are all two switches OK Y N Replace faulty switch Measure for continuity between J14 18 and J14 19 between J25 3 and J25 4 Is there continuity in both cables Y N Replace wire harness Replace PCB FTR 202 Fault Code FTR 202 indicates that at initia...

Page 57: ...he Trim bin full sensor FTR Q8 is faulty Procedure Is there something blocking the Trim bin full sensor FTR Q8 Y N Go to FTR 018 fault code Remove the object and empty the Trim bin 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 inst...

Page 58: ...tial 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 Y N Go to FTR 014 fault code Replace PCB FTR 503 Fault Code FTR 503 indicates that the stacker is full If fault occurs erronous see FTR 204 ...

Page 59: ...FTR 4 14 Page intentionally blank ...

Page 60: ...Service Tables FTR 5 1 29 November 2006 5 SERVICE TABLES 5 1 SERVICE TABLES Trimmer service tables is located in the Booklet Maker BM 200 Service Manual 5 ...

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Page 62: ... FTR 6 2 FTR Q4 Transport belt sensor FTR 6 2 FTR Q5 Trim knife home position sensor FTR 6 2 FTR Q6 Outfeed sensor FTR 6 2 FTR Q7 Paper stop gate home position sensor FTR 6 5 FTR Q8 Trim bin full sensor FTR 6 3 FTR S9 Interlock switch FTR 6 3 FTR Q130 Interlock magnet FTR 6 3 FTR S11 Length adjustment home position switch FTR 6 5 FTR Q12 Length adj motor sensor loc on mot M4 FTR 6 5 PCB MD6DC PCB ...

Page 63: ... 2 29 November 2006 6 1 1 REAR VIEW FTR S2 FTR S3 FTR Q4 FTR Q5 MD6DC PCB A Safety block for knife Stacker Receptacle Power Supply Trimmer COM BM 200 Terminator COM SQF 200 ELECTRICAL COMPONENT LIST Counter ...

Page 64: ...Detailed description FTR 6 3 29 November 2006 6 1 2 INFEED VIEW FTR M1 FTR M2 FTR Q13 FTR Q8 Interlock Switch FTR S9 Q130 FTR M5 M6 ELECTRICAL COMPONENT LIST ...

Page 65: ...FTR 6 4 29 November 2006 6 1 3 OUTFEED VIEW FTR Q6 FTR M2 FTR M1 ELECTRICAL COMPONENT LIST ...

Page 66: ...Detailed description FTR 6 5 29 November 2006 6 1 4 STOP CARRIAGE VIEW FTR M3 FTR M4 FTR Q12 FTR Q7 FTR S11 ELECTRICAL COMPONENT LIST ...

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Page 68: ...Detailed description FTR 6 7 29 November 2006 6 2 BOARD STRUCTURE 6 2 1 BLOCK DIAGRAM Interlock magnet ...

Page 69: ... 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: ...Detailed description FTR 6 9 29 November 2006 6 2 2 CONTROLLER MD6DC CONTINUES FTR M2 FTR M1 FTR M4 FTR M3 ST M1 Set counter FTR M5 FTR M6 ...

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Page 72: ...Detailed description FTR 6 11 29 November 2006 6 3 TRIMMING PROCESS 6 3 1 PRINCIPLE OF OPERATION TRIMMING PROCESS FTR M2 FTR Q6 FTR M1 FTR Q13 FTR Q4 FTR Q5 ...

Page 73: ...tor FTR M1 is triggered by knife position sensor FTR Q5 to reverse and helps knife motor FTR M2 during the cutting stroke About the time when the knife has cut through the sheets the stop gate motor FTR M3 moves the stop gate down and the transport motor FTR M1 reverses again to transport the set out of the machine The knife motor completes its cycle and stops at the trim knife home position senso...

Page 74: ...arts 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 When the switch FTR S11 is activated a counter for the motor FTR M4 starts and the motor FTR M4 reverses The motor FTR M4 runs until length adjustment motor sensor FTR Q12 has counted the preset amount of pulses set by the paper size and tri...

Page 75: ...4 when correct amount of pulses are received Stop gate is now in cor rect position corresponding to the new paper size selected If paper jam occurs If top cover is opened and closed Stop gate motor FTR M3 moves the stop gate down Length adjustment 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 Tr...

Page 76: ...FTR Spc 1 29 November 2006 Specification SPECIFICATIONS SPECIFICATIONS Trimmer specifications is located in the Booklet Maker BM 200 Service Manual SPECIFICATIONS ...

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Page 78: ...FTR Wir 1 29 November 2006 Wiring WIRING Trimmer See pocket at rear of manual for wiring diagrams ...

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