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FB8X Service Manual Rev. C, 9/28/10

iii

C O N T E N T S

1 SUMMARY

2 OVERVIEW

2.1 Main Components of the FB8x

2.2 Diagram of the User Menu

2.3 System Block Diagram

2.4 Specifications

2.5 Bind Media

2.6 Getting the Best Bind Quality

2.7 Contacting Technical Support

3 REQUIRED SERVICE TOOLS

3.1 Hand Tools

3.2 Tools to Service the Heaters

3.3 Tools for Flash Upgrade of the Microcontroller

3.4 Tools needed to inspect the Controller Assembly

3.5 Cleaning Supplies

4 TROUBLESHOOTING

4.1 Power Problems

4.2 Error Messages

4.3 Machine Errors

4.4 Display Problems

4.5 Poor Bind Quality

5 SERVICE MENU

5.1 Accessing the Service Menu

5.2 Diagram of the Service Menu

5.3 Service Menu Descriptions

5.4 Testing and Calibration

5.4.1 Measuring the Heater Temperature

5.4.2 Checking the Sensors

5.4.3 Calibrating the Sensors, the Switches, and the Carriage Assembly

5.4.4 Entering the A_HI/A_LO values

5.4.5 Checking Motor Functions

5.4.6 Checking the Resistance of the Heater Sensors

5.4.7 Checking the Resistance of the Heater Power Connectors

Содержание Fastback 8x

Страница 1: ...MODEL 8x DOCUMENT BINDER Service Manual...

Страница 2: ...d under the copyright laws Warranty The information contained in this document is subject to change without notice Powis Parker makes no warranty of any kind with respect to this information Powis Par...

Страница 3: ...the Controller Assembly 3 5 Cleaning Supplies 4 TROUBLESHOOTING 4 1 Power Problems 4 2 Error Messages 4 3 Machine Errors 4 4 Display Problems 4 5 Poor Bind Quality 5 SERVICE MENU 5 1 Accessing the Ser...

Страница 4: ...ler Assembly 6 3 3 Changing the Fuses 6 4 Carriage Drive 6 5 Bender Drive 6 6 Sensors 6 6 1 Strip Present PCA 6 6 2 Book Emitter PCA 6 6 3 Book Detector PCA 6 7 Switches 6 7 1 Carriage Home Switch 6 7...

Страница 5: ...ch the Model 8x binds documents has not changed The Model 8x has three heaters located in the binding recess that heat the adhesive coating on the Lx Strip or the spine on the Halfback Cover and adher...

Страница 6: ...ly Carriage Home Switch Spine Spring Left Carriage Guide Jaw Guide Carriage Alignment Plate O V E R V I E W M a i n C o m p o n e n t s 2 1 M A I N C O M P O N E N T S O F T H E F B 8 x 2 Binder with...

Страница 7: ...0 Page 3 Book Sense Emitter PCA Bender Motor Assembly O V E R V I E W M a i n C o m p o n e n t s 2 1 M A I N C O M P O N E N T S O F T H E F B 8 x Strip Detector PCA Bender Heater 2 Picture shows Tam...

Страница 8: ...O V E R V I E W M a i n C o m p o n e n t s 2 2 1 M A I N C O M P O N E N T S O F T H E F B 8 x Carriage Clamp Switch Carriage Spring Spine Heater Cooling Platen Carriage Assembly Back Heater Picture...

Страница 9: ...J11 J2 J3 J1 J4 J5 J6 J7 J1 Spine Heater Temp Sensor Connector J2 Bender Heater Temp Sensor Connector J3 Back Heater Temp Sensor Connector J4 Motors Connector J5 Spine Heater Power Connector J6 Bende...

Страница 10: ...ONDS 0 SECONDS 1 SECONDS 2 SECONDS 3 SECONDS 4 SECONDS 5 SECONDS 0 SECONDS 5 SECONDS 10 SECONDS 15 SECONDS 20 SECONDS 2 SECONDS 5 SECONDS DUTCH DEUTSCH FRANCAIS ITALIANO ESPA OL NORSK ENGLISH SVENSKA...

Страница 11: ...FB8X Service Manual Rev C 9 28 10 Page 7 O V E R V I E W S y s t e m B l o c k D i a g r a m 2 2 3 S y s t e m B l o c k D i a g r a m...

Страница 12: ...H x 12 5 D Without book fences attached 19 3 W x 6 0 H x 10 6 D Bind Capacity Lx Strip 04 to 1 0 1 mm to 25 mm about 10 250 sheets 10 125 sheets Narrow Lx Strip 126 250 sheets Medium Lx Strip L Strip...

Страница 13: ...Strips Selecting the Binding Mode To bind with any of these various binding strips enter the User Menu and select the binding strip you wish to bind with Bind Memory When the machine is turned off an...

Страница 14: ...long way lightly in your fingertips and gently bow the paper allowing it to flex Now try it the other way See the difference Most copy papers are grain long so you should not have any problems with th...

Страница 15: ...11 O V E R V I E W T e c h n i c a l A s s i s t a n c e 2 If there are any questions not answered in this manual please contact the Powis Parker Technical Support Dept 510 848 2463 2 7 C o n t a c t...

Страница 16: ...Page 12 FB8X Service Manual Rev C 9 28 10 O V E R V I E W 2 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Страница 17: ...Key Pen Exacto Knife 3 2 TOOLS TO SERVICE THE HEATERS Temperature Meter K 820 011 Straight Temperature Probe K 820 012 Right Angle Temperature Probe K 820 3436 Ohmmeter 3 3 TOOLS FOR FLASH UPGRADE OF...

Страница 18: ...roller Assembly NO POWER Possible Cause Solution A 230v machine in plugged into a 115v outlet Plug the machine into a 230v outlet Failed Controller Assembly Replace the Controller Assembly POWER FLICK...

Страница 19: ...ing to bind too few sheets with a medium strip Add some sheets or use a narrow width strip There is no strip in the binding recess Insert a narrow strip Possible Cause Solution The strip is inserted i...

Страница 20: ...r malfunction Check the resistance of the Heaters See Section 5 4 6 Checking the Resistance of the Heater Sensors Heater calibration is inaccurate Recalibrate the heaters See Section 5 3 2 Cal Heaters...

Страница 21: ...re Check the function of both switches in the CHECK SENSORS menu Replace any damaged switches Obstructions in the binding recess Check for obstructions in the binding recess If necessary remove the Ca...

Страница 22: ...Flash Upgrade again with the current firmware Failed Controller Assembly Replace the Controller Assembly Error Message FIRMWARE ERROR Possible Cause Solution Heater A_HI A_LO values are incorrect Ver...

Страница 23: ...ay Failed Display Replace the Display Failed Controller Assembly Replace the Controller Assembly NO CHARACTER DISPLAYED Possible Cause Solution Failed Display Replace the Display Failed Controller Ass...

Страница 24: ...eft sides of the pages until the edges are even The Strip is not flush against the right side of the binding recess Make sure the strip is flush against the right side of the binding recess PAGES PROT...

Страница 25: ...FB8X Service Manual Rev C 9 28 10 Page 21 T R O U B L E S H O O T I N G G U I D E 4 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Страница 26: ...Page 22 FB8X Service Manual Rev C 9 28 10 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Страница 27: ...M CHECK appears on the screen an OK message should appear followed by the date of the currently installed firmware After a couple seconds AUTO CYCLES will appear 5 1 1 Navigating through the Service M...

Страница 28: ...Page 24 FB8X Service Manual Rev C 9 28 10 S E R V I C E M E N U 5 5 2 S e r v i c e M e n u D i a g r a m...

Страница 29: ...FB8X Service Manual Rev C 9 28 10 Page 25 S E R V I C E M E N U 5 5 2 S e r v i c e M e n u D i a g r a m...

Страница 30: ...ALIBRATION This option allows you to calibrate the Book Sensor the Strip Sensor the Carriage Assembly and the Heaters CAL BOOK SENSOR Selecting this menu option will allow you to calibrate the Book Se...

Страница 31: ...lue is in the acceptable range or an NG message if the out of range CARR XX OK NG This menu option displays the carriage calibration value There will be an OK if the value is in the acceptable range o...

Страница 32: ...st value should be 2750 150 The second value should be between 100 and 2400 The numbers will change from moment to moment but should not vary by no more than 100 CHECK HEATER SN This menu displays thr...

Страница 33: ...he display The diagnostic values are for use by Powis Parker technicians only TEST BENDER Selecting this menu will allow you to turn on the Bender Heater only Press the BIND button to turn the heater...

Страница 34: ...s SPINE HIGH This menu allows for viewing and editing of the A_HI value of the Spine Heater SPINE LOW This menu allows for viewing and editing of the A_LO value of the Spine Heater BENDER HIGH This me...

Страница 35: ...display will read UP and a value will appear This value should be 50 5 After moving the Bender Heater down the display will read DOWN and a value will appear This value should be 0 5 BENDER2 In this...

Страница 36: ...ne Heater press the orange OPEN button Turn off the machine if the temperature exceeds 350 F 177 C Then contact Powis Parker Technical Service 5 4 1 MEASURING HEATER TEMPERATURE To measure the tempera...

Страница 37: ...Bender Heater press the orange OPEN button Turn off the machine if the temperature exceeds 260 F 127 C Then contact Powis Parker Technical Service CHECKING THE BACK HEATER TEMPERATURE 1 Enter HEATERS...

Страница 38: ...0 0 0 Checking the Book Sensor To activate the Book Sensor insert a piece of paper into the binding recess as shown The third number will turn to 3 when the Book Sensor is blocked Checking the Strip...

Страница 39: ...alternate between 0 and 1 Checking the Carriage Clamp Switch To check the Carriage Clamp Switch the Carriage Assembly must be moved forward out of it s home position Remove the Right Cover making sur...

Страница 40: ...Assembly enter the service menu and select CALIBRATION 2 Select CAL CARRIAGE 3 Make sure there is nothing in the binding recess Press the BIND button 4 A confirmation message CAL NOW will appear on th...

Страница 41: ...he display Press the Bind button to confirm that you want to edit the value 6 A_HI XXX X will appear on the display with the last value blinking Enter the A_HI or A_LO value starting with the last val...

Страница 42: ...e orange MENU button to rotate the Bender Heater down and the green BIND button to rotate the Bender Heater up 5 4 T E S T I N G A N D C A L I B R A T I O N When the Carriage Assembly closes three num...

Страница 43: ...ng the Bender Motor in the BENDER2 menu 1 Enter the MOTORS menu 2 Select BENDER2 3 Press the orange MENU button or the green BIND button to rotate the Bender Heater in the down position the halfway po...

Страница 44: ...1 J2 J3 4 Touch the red and black probes to each connector as shown 5 Verify all Heater sensor connectors have a reading of 120 ohm 15 at 20 C 68 F J1 Spine Heater Connector J3 Back Heater Connector J...

Страница 45: ...rify the readings on the Ohmmeter are as follows HEATER RESISTANCE J5 SPINE HEATER 115v 100v 27 ohm 15 J5 SPINE HEATER 230v 108 ohm 15 J6 BENDER HEATER 115v 100v 46 ohm 15 J6 BENDER HEATER 230v 186 oh...

Страница 46: ...two screws on the underside of the machine flip the binder on its back end to prevent scratching the top surface of the binder To fully remove the Right Cover remove the three screws and then unplug...

Страница 47: ...g places in the base fig 4 2 Reattach the Skirt S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 Removing the Cooling Rack 1 Remove the Right and Left Covers 2 Remove the Cooling Rack T...

Страница 48: ...es the best access to the Heater Connections Fig 2 Fig 1 Fig 3 S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 6 3 2 Removing the Controller Assembly 1 Disconnect the power cord from t...

Страница 49: ...attach to the back of the Base Plate using the two M4x6 Screws fig 3 6 3 3 Changing the Fuses 1 Disconnect the Power Cord 2 Prop the machine up and drop the Controller Assembly down 3 Use a fuse pulle...

Страница 50: ...ove the Carriage Assembly forward so that the two screws attaching the Drive Nut Bracket are accessible fig 3 This will ensure that no damage is done to the sensor board on the Carriage Drive Motor 6...

Страница 51: ...e Drive does not pinch the Carriage Home Switch fig 3 2 Place the Carriage Back Guide against the Right Carriage Guide in the orientation shown fig 4 3 Attach the Drive Nut Bracket to the Drive Nut as...

Страница 52: ...ve Installing the Bender Drive 1 Connect the Wire Harness connector to the Bender Drive 2 Insert the Bender Drive through the hole in the Right Side Plate making sure the sensor board is pointing towa...

Страница 53: ...Screw attaching the Strip Sensor to the Bracket Installing the Strip Present PCA 1 Attach the Strip Sensor to the Strip Sensor Bracket using one M3x6 LG PH PHIL Screw 2 Attach the Strip Sensor bracket...

Страница 54: ...Book Sense Emitter PCA 1 Attach the Book Emitter PCA to the Tamping Platform using one M4x8 PH PHIL Screw 2 Connect the Wire Harness connector fig 4 3 Reinstall the Front Cover After replacing the Bo...

Страница 55: ...ig 3 3 Reattach the Carriage Top using the four M3x12 FH PHIL Screws and mak ing sure the top edge of the PCA fits into the slot on the underside of the plate 4 Reinstall the Carriage Assembly 5 Reins...

Страница 56: ...nside the machine Installing the Carriage Home Switch 1 Insert the Carriage Home Switch wire through the hole in the Right Side Plate and connect it to the Wire Harness fig 2 2 Attach the Switch to th...

Страница 57: ...ng a 1 8 wide cable tie 4 Verify the little black cable tie on the Switch s wire is next to the 1 8 Cable tie Trim excess on 1 8 cable tie 6 8 D i s p l a y Removing the Display 1 Remove the Right Cov...

Страница 58: ...nnect the Bender Heater connec tions from the Controller Assembly Installing the Bender Assembly 1 Insert the tabs on the Bender Pivots into the holes on the ends of the Bender Heater fig 4 2 Attach t...

Страница 59: ...Left Carriage Guide by unscrewing the two M3x10 PH PHIL Screws fig 2 7 Remove the two M4x20 PH PHIL Screws attaching the Drive Nut Plate the Right Carriage Guide and the Carriage Back Guide fig 3 8 R...

Страница 60: ...to the slot making sure the tabs are facing outward Push the Carriage Guide all the way back fig 5 7 Move the Carriage Assembly back Flip the Drive Nut Bracket up so that the holes engage the two tabs...

Страница 61: ...Left Side Plate fig 6 3 Attach the two Spine Pivot Pins making sure the groove is near the side plates 4 Attach the two 7mm Retaining Rings into the Spine Pivot Pins fig 7 8 5 Install the Carriage Al...

Страница 62: ...Shroud over the Fan and attach using M4x20 Pan Head Screws making sure that no wires are being pinched under the Fan or Shroud En sure the Fan Shroud is oriented so that the open end is facing the Con...

Страница 63: ...ssembly 7 Remove the two Jaw Guides from the Jaw Assembly Installing the Jaw Assembly 1 Attach the Jaw Guide to the right side of the Jaw Assembly fig 1 After you hear the jaw guide click into place p...

Страница 64: ...Section 6 11 Replacing the Grip Tape on the Carriage Assembly 1 Remove the Carriage Assembly as outlined in Section 6 9 2 2 Carefully peal off the existing Grip Tape 3 Remove the Hot Symbol Label 4 Cl...

Страница 65: ...FB8X Service Manual Rev C 9 28 10 Page 61 S E R V I C E A N D C A L I B R A T I O N P R O C E D U R E S 6 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Страница 66: ...N G F I R M W A R E 7 7 1 T o o l s R e q u i r e d P31 Printer Cable K 551 1685 FB8x P31 Printer Cable K 551 1685 PC with either Windows 98 2000 XP ME or Vista and a 9 pin com port FB8x Flash Update...

Страница 67: ...re No installation procedure is required for this software Just save the exe file in an easy to find location 1 Download the latest FB8x firmware from the Powis Parker website The hex file that will c...

Страница 68: ...e com port turn the FB8x ON After 0 10 seconds the FB8x LCD should say LOADER RUNNING and the NEXT button in the Flash Upgrade window should darken and become available Click the NEXT button NOTE If L...

Страница 69: ...top right corner of the window 8 A file selection dialog window will appear Find and select the hex file that contains the new firmware Click NEXT NOTE If you choose an incorrect or corrupt file you w...

Страница 70: ...e d u r e 9 A Review and Conformation window will appear This window contains summary information about the firmware that is currently on the FB8x and the firmware you are about to install The Flash...

Страница 71: ...ss of the firmware transfer and a space for additional information about the setup process Any additional steps needed for this upgrade will appear in this window Click the FINISH button to exit the F...

Страница 72: ...Page 68 FB8X Service Manual Rev C 9 28 10 U P G R A D I N G F I R M W A R E 7 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Страница 73: ...mbly D J K A4102E Service Kit Bender Assembly E K A4104D Service Kit Carriage Assembly D J K A4104E Service Kit Carriage Assembly E K A4641 Service Kit Fuse Kit K A4687 Service Kit Spring Kit K A4708...

Страница 74: ...l Out Instruction Card 1 Screw FH Phl M3x 5x6mm Zi 1 Screw PH Phil M3x10 Lg Plastite 2 K 410 3996 Service Kit Cooling Rack Item Qty Cooling Rack 1 K A3926 02 Service Kit Right Cover Assembly Item Qty...

Страница 75: ...PCA 1 Book Sense Detector PCA 1 K A3931 Service Kit Display Assembly Item Qty Display Assembly 1 K A4092D Controller Assembly D NON RoHS K A4092E Controller Assembly E NON RoHS K A4092J Controller Ass...

Страница 76: ...rvice Kit Bender Assembly D J K A4102E Service Kit Bender Assembly E Item Qty Bender Assembly 1 K A4104D Service Kit Carriage Assembly D J K A4104E Service Kit Carriage Assembly E Item Qty Carriage As...

Страница 77: ...sembly Item Qty Bender Motor Assembly 1 K A3933 Service Kit Carriage Drive Assembly Item Qty Carriage Drive Assembly 1 K A4008 Carriage Shaft Alignment Assembly Item Qty Carriage Shaft Alignment Assem...

Страница 78: ...Spring 2 K A4710 Service Kit Plastic Part Kit Item Qty Bender Gear 1 Jaw Guides 2 Right Bender Pivot 1 Left Bender Pivot 1 Spine Pivot Pin 2 Left Carriage Guide 1 Right Carriage Guide 1 K A4711 Servic...

Страница 79: ...h Soc M3x 5x6 LG 4 Screw Fh Phil M3x 5x12 LG 16 Screw Sem Ph Phl M3x 5x6 LG 28 Screw Sem Ph Phl M3x 5x12 LG 16 Screw Ph Phl M3x 5x10mm Zi 4 Screw Ph Phl M3x 5x6mm Zi 4 Screw SH Cap M3x 5 Lg Blk 4 Scre...

Страница 80: ...E F B 8 x P A R T I A L L Y E X P L O D E D 10 1 2 3 4 5 ITEM DESCRIPTION 1 Cooling Rack 2 Left Cover 3 Right Cover Assembly 4 Front Cover 5 Skirt Note The Pull Out Instructions Card and the Book Supp...

Страница 81: ...SCRIPTION 1 Carriage Assembly Back Heater 2 Left Carriage Guide 3 Carriage Spring 4 Carriage Guide Back 5 Right Carriage Guide 6 Drive Nut Bracket 7 Carriage Drive Assembly 8 Controller Assembly 9 Car...

Страница 82: ...D E D 10 ITEM DESCRIPTION 1 Jaw Assembly 2 Jaw Guide 3 Carriage Home Switch 4 Tamping Platform 5 Bender Motor Assembly 6 Bender Gear 7 Bender Link 8 Left Bender Pivot 9 Bender Assembly 10 Right Bende...

Страница 83: ...FB8X Service Manual Rev C 9 28 10 Page 79 P I C T U R E S O F T H E M A C H I N E P A R T I A L L Y E X P L O D E D 10 THIS PAGE IS INTENTIONALLY LEFT BLANK...

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